Wafer-level flip chip device packages and related methods

ABSTRACT

In accordance with certain embodiments, semiconductor dies are at least partially coated with a polymer and a conductive adhesive prior being bonded to a substrate having electrical traces thereon.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/523,433, filed Oct. 24, 2014, which is a continuation of U.S. patentapplication Ser. No. 13/949,546, filed Jul. 24, 2013, which (i) claimsthe benefit of and priority to U.S. Provisional Patent Application No.61/790,441, filed Mar. 15, 2013, and (ii) is a continuation-in-part ofU.S. patent application Ser. No. 13/748,864, filed Jan. 24, 2013, whichclaims the benefit of and priority to U.S. Provisional PatentApplication No. 61/589,908, filed Jan. 24, 2012, and U.S. ProvisionalPatent Application No. 61/589,909, filed Jan. 24, 2012, the entiredisclosure of each of which is hereby incorporated herein by reference.

FIELD OF THE INVENTION

In various embodiments, the present invention relates to the fabricationof an encapsulated wafer-level flip chip package by use of encapsulationand a conductive adhesive.

BACKGROUND

Involved in all procedures of the production of final products fromsemiconductor devices, an electronic packaging technology is a systemfabrication methodology covering a wide range of versatile techniques.With great advances in technology in recent years, semiconductorfabrication techniques have enabled the integration of one million ormore cells, the multiplication of I/O pins, the enlargement of diesizes, the rapid radiation of large amounts of heat, and the highelectrical performance of semiconductor devices. However, the progressof electronic packaging technology, which is utilized to encapsulatethese semiconductor devices in some form of sealed package so as toprotect them from external or internal damage, has consistently laggedbehind the progress of semiconductor fabrication techniques.

In determining the performance, dimension, price and reliability of afinal semiconductor device product, the electronic package technology isone of the most important factors. Chips 20 are typically fabricated ona wafer, for example wafer 10 shown in FIG. 1. The wafer is thensingulated, i.e., separated into individual chips for subsequentpackaging. Packaging generally includes putting the chip into a packageas well as electrical connection of the chip I/O pins to the packagecontacts. A variety of packages and electrical connection methods havebeen developed. In one approach, wire bonding is used to connect thechip I/O pins to the package contacts. Wire bonding may be timeconsuming, and the wires may be relatively fragile and may requirerelatively large amounts of space within the package. A flip-chipapproach may also be used. In the flip-chip process, a chip isfabricated with contacts on its top surface and then flipped forattachment of those contacts to a substrate (e.g., a circuit board).However, this has a drawback in that the production efficiency is poorin terms of process complexity and product cost because it typicallyrequires conventional solder-using complex connection processes, thatis, solder flux coating, chip/board arranging, solder bump reflowing,flux removing, underfill filling and curing processes. Moreover,flip-chip processes are generally performed on individually,pre-singulated devices, and thus uniformity and repeatability are oftenproblematic.

In some applications, it is desirable to encapsulate the chip, forexample to encapsulate a flip chip. This may be done for a variety ofreasons, for example to protect the chip or to provide some enhancedfunctionality by virtue of the encapsulation. Such encapsulation isoften performed on individually, pre-singulated devices, resulting inrelatively high cost and, in the case where the encapsulation providesenhanced functionality, the uniformity and repeatability of this areoften problematic. For example in the case of light-emitting devices,for example light-emitting diodes (LEDs), the encapsulant may provideenhanced functionality by including a light-conversion material thatabsorbs a portion of the light emitted by the LED and re-emits it at adifferent wavelength. Such a configuration may be used to produce lightof different colors or different spectral power distributions. In oneexample, the LED emits light in the UV to blue wavelength range, and thecombination of the LED and the light-conversion material producessubstantially white light. Performing such encapsulation on anindividual die basis (i.e., die-by-die) may result in variations incolor (for example white point), resulting in low yield and increasedcost.

In view of the foregoing, there is a need for a more uniform and lesscomplex flip-chip-based packaging process for electronic devicesfabricated on semiconductor substrates.

SUMMARY

Embodiments of the present invention provide techniques for fabricatinga large-scale or wafer-level flip-chip package, which is advantageous interms of production cost by simplifying the processes associated withthe flip-chip die attachment process. Embodiments of the presentinvention simplify the processes necessary for encapsulation andconnection of chips to a final substrate by, e.g., forming theencapsulation and enabling electrical connecting at the wafer levelinstead of at the individual die level.

In accordance with certain embodiments, semiconductor dies such aslight-emitting elements (LEEs) are coated with a polymeric binder, whichis subsequently cured to form a composite wafer of the solid bindermaterial with the dies suspended therein. The contacts of eachsemiconductor die remain at least partially uncoated by the binder. Ananisotropic conductive adhesive (ACA) may then be applied over the sideof the solid binder material from which the uncoated contacts protrude.Techniques utilized in embodiments of the invention may include thosedisclosed in U.S. patent application Ser. Nos. 13/784,417 and13/784,419, both filed on Mar. 4, 2013, the entire disclosures of whichare incorporated by reference herein.

The composite wafer may be divided into free-standing “white dies” (or“coated dies”) each containing a die, a portion of the cured binder thatat least partially surrounds the die, and a portion of the ACA thatcovers the contacts and enables electrical connection thereto (throughthe ACA). The binder may advantageously contain a wavelength-conversionmaterial such as a phosphor or a collection of quantum dots. Variousmold substrates and/or molds may be utilized to secure the semiconductordies and/or to prevent coating of the contacts of the dies during thecoating process. In accordance with embodiments of the presentinvention, each white die may then be bonded to, e.g., heat-pressedagainst, a substrate so that the individual chips are electricallyconnected via the conductive particles of the ACA and physically bondedvia the polymeric resin of the ACA to conductive traces on thesubstrate. In some embodiments, solder or stud bumps may be applied tothe contacts before formation of the ACA over the contacts. In someembodiments, the bonding may be accomplished using energy sources otherthan heat to cure the ACA, for example UV radiation may be used. In oneembodiment of the present invention, a yielding, i.e., flexible and/ordeformable, substrate is used, which facilitates the connection betweencontacts on a chip and conductive traces formed over the yieldingsubstrate without the use of solder or non-solder bumps, as detailed inU.S. patent application Ser. No. 13/171,973, filed on Jun. 29, 2011, theentire disclosure of which is incorporated by reference herein. In someembodiments, the substrate is “flexible” in the sense of being pliant inresponse to a force and resilient, i.e., tending to elastically resumean original configuration upon removal of the force. A substrate may be“deformable” in the sense of conformally yielding to a force, but thedeformation may or may not be permanent; that is, the substrate may notbe resilient. Flexible materials used herein may or may not bedeformable (i.e., they may elastically respond by, for example, bendingwithout undergoing structural distortion), and deformable substrates mayor may not be flexible (i.e., they may undergo permanent structuraldistortion in response to a force). The term “yielding” is herein usedto connote a material that is flexible or deformable or both.

As utilized herein, the term “light-emitting element” (LEE) refers toany device that emits electromagnetic radiation within a wavelengthregime of interest, for example, visible, infrared or ultravioletregime, when activated, by applying a potential difference across thedevice or passing a current through the device. Examples of LEEs includesolid-state, organic, polymer, phosphor-coated or high-flux LEDs,microLEDs (described below), laser diodes or other similar devices aswould be readily understood. The emitted radiation of a LEE may bevisible, such as red, blue or green, or invisible, such as infrared orultraviolet. A LEE may produce radiation of a spread of wavelengths. ALEE may feature a phosphorescent or fluorescent material for convertinga portion of its emissions from one set of wavelengths to another. A LEEmay include multiple LEEs, each emitting essentially the same ordifferent wavelengths. In some embodiments, a LEE is an LED that mayfeature a reflector over all or a portion of its surface upon whichelectrical contacts are positioned. The reflector may also be formedover all or a portion of the contacts themselves. In some embodiments,the contacts are themselves reflective.

A LEE may be of any size. In some embodiments, a LEEs has one lateraldimension less than 500 μm, while in other embodiments a LEE has onelateral dimension greater than 500 um. Exemplary sizes of a relativelysmall LEE may include about 175 μm by about 250 μm, about 250 μm byabout 400 μm, about 250 μm by about 300 μm, or about 225 μm by about 175μm. Exemplary sizes of a relatively large LEE may include about 1000 μmby about 1000 μm, about 500 μm by about 500 μm, about 250 μm by about600 μm, or about 2000 μm by about 2000 μm. In some embodiments, a LEEincludes or consists essentially of a small LED die, also referred to asa “microLED.” A microLED generally has one lateral dimension less thanabout 300 μm. In some embodiments, the LEE has one lateral dimensionless than about 200 μm or even less than about 100 μm. For example, amicroLED may have a size of about 225 μm by about 175 μm or about 150 μmby about 100 μm or about 150 μm by about 50 μm. In some embodiments, thesurface area of the top surface of a microLED is less than 50,000 μm² orless than 10,000 μm². The size of the LEE is not a limitation of thepresent invention, and in other embodiments the LEE may be relativelylarger, e.g., the LEE may have one lateral dimension on the order of atleast about 1000 μm or at least about 3000 μm.

As used herein, “phosphor” refers to any material that shifts thewavelengths of light irradiating it and/or that is fluorescent and/orphosphorescent. As used herein, a “phosphor” may refer to only thepowder or particles (of one or more different types) or to the powder orparticles with the binder, and in some circumstances may refer toregion(s) containing only the binder (for example, in a remote-phosphorconfiguration in which the phosphor is spaced away from the LEE). Theterms “wavelength-conversion material” and “light-conversion material”are utilized interchangeably with “phosphor” herein. Thelight-conversion material is incorporated to shift one or morewavelengths of at least a portion of the light emitted by LEEs to other(i.e., different) desired wavelengths (which are then emitted from thelarger device alone or color-mixed with another portion of the originallight emitted by the LEE). A light-conversion material may include orconsist essentially of phosphor powders, quantum dots, organic dyes, orthe like within a transparent binder. Phosphors are typically availablein the form of powders or particles, and in such case may be mixed inbinders. An exemplary binder is silicone, i.e., polyorganosiloxane,which is most commonly polydimethylsiloxane (PDMS). Phosphors vary incomposition, and may include lutetium aluminum garnet (LuAG or GAL),yttrium aluminum garnet (YAG) or other phosphors known in the art. GAL,LuAG, YAG and other materials may be doped with various materialsincluding for example Ce, Eu, etc. The specific components and/orformulation of the phosphor and/or matrix material are not limitationsof the present invention.

The binder may also be referred to as an encapsulant or a matrixmaterial. In one embodiment, the binder includes or consists essentiallyof a transparent material, for example silicone-based materials orepoxy, having an index of refraction greater than 1.35. In oneembodiment the binder and/or phosphor includes or consists essentiallyof other materials, for example fumed silica or alumina, to achieveother properties, for example to scatter light, or to reduce settling ofthe powder in the binder. An example of the binder material includesmaterials from the ASP series of silicone phenyls manufactured by ShinEtsu, or the Sylgard series manufactured by Dow Corning.

Herein, two components such as light-emitting elements and/or opticalelements being “aligned” or “associated” with each other may refer tosuch components being mechanically and/or optically aligned. By“mechanically aligned” is meant coaxial or situated along a parallelaxis. By “optically aligned” is meant that at least some light (or otherelectromagnetic signal) emitted by or passing through one componentpasses through and/or is emitted by the other.

Herein, a contact being “available for electrical connection” means thecontact has sufficient free area to permit attachment to, e.g., aconductive trace, a circuit board, etc., and “free” means lacking anyelectrical connection (and in preferred embodiments, any mechanicalconnection) thereto.

In an aspect, embodiments of the invention feature an electronic deviceincluding or consisting essentially of a solid shaped volume of apolymeric binder, a bare-die light-emitting diode suspended within thebinder, and an ACA. The bare-die light-emitting diode has a first face,a second face opposite the first face, and at least one sidewallspanning the first and second faces. At least two spaced-apart contactsare disposed on the first face of the bare-die light-emitting diode. Thecontacts each have a terminal end not covered by the binder. The ACA isdisposed under at least a portion of the polymeric binder and in contactwith the terminal ends of the contacts. At least a portion of the binderis transparent to a wavelength of light emitted by the light-emittingdiode. The binder includes or consists essentially of silicone and/orepoxy with a wavelength-conversion material therein. At least a portionof the ACA opposite the contacts is available for electrical connection(i.e., available to make an electrical connection therethrough from thecontacts of the light-emitting diode to another conductive layer ordevice (i.e., electrical traces) on the opposite side of the ACA).

Embodiments of the invention may include one or more of the following inany of a variety of combinations. At least portions of the contacts mayprotrude from the binder. Only a portion of each said sidewall (i.e., aportion but not all of each sidewall) may protrude from the binder. Thewavelength-conversion material may include or consist essentially of aphosphor and/or quantum dots. The light-emitting diode may include orconsist essentially of a semiconductor material including or consistingessentially of GaAs, AlAs, InAs, GaP, AlP, InP, ZnO, CdSe, CdTe, ZnTe,GaN, AlN, InN, silicon, and/or an alloy or mixture thereof. Thewavelength-conversion material may absorb at least a portion of lightemitted from the bare-die light-emitting diode and emit converted lighthaving a different wavelength, converted light and unconverted lightemitted by the bare-die light-emitting diode combining to formsubstantially white light. The substantially white light may have acorrelated color temperature in the range of 2000 K to 10,000 K. Areflecting layer may be disposed between at least a portion of thebinder and the ACA. The reflecting layer may include or consistessentially of a reflecting film and/or a plurality of reflectiveparticles. At least a portion of a surface of the binder may have atexture having heights above the surface selected from the range ofabout 0.25 μm to about 15 μm. The texture may include or consistessentially of a substantially random surface roughness or a periodic ornon-periodic array of features. The ACA may include or consistessentially of an anisotropic conductive film disposed on the binder andthe contacts.

In another aspect, embodiments of the invention feature a method forforming a composite wafer including or consisting essentially of aplurality of discrete semiconductor dies suspended in a cured binder.The plurality of discrete semiconductor dies are disposed on a moldsubstrate. Each semiconductor die has at least two spaced-apart contactsdisposed in contact with the mold substrate. The semiconductor dies arecoated with a binder. The binder is cured to form the composite wafer,and the contacts of each semiconductor die remain at least partiallyuncoated by the binder. An ACA is applied over at least a portion of thecomposite wafer including at least a portion of binder and the at leastpartially uncoated contacts. At least a some of the semiconductor diesare bare-die light-emitting diodes. At least a portion of the binder istransparent to a wavelength of light emitted by the light-emittingdiodes. The binder includes a wavelength-conversion material therein.

Embodiments of the invention may include one or more of the following inany of a variety of combinations. The ACA may include or consistessentially of an anisotropic conductive film. The ACA may be appliedover substantially the entire composite wafer. The ACA may be appliedover all of the contacts of the composite wafer but not over a portionof the binder. The composite wafer may be singulated, before or afterthe composite wafer is separated from the mold substrate, into aplurality of devices each including or consisting essentially of (i) atleast one semiconductor die, (ii) at least a portion of the binderdisposed around the at least one semiconductor die, and (iii) a portionof the ACA disposed in contact with contacts of the at least onesemiconductor die. At least portions of the contacts may protrude fromthe binder after the semiconductor dies are coated with the binder. Onlya portion (i.e., some but not all) of each said sidewall may protrudefrom the binder after the semiconductor dies are coated with the binder.The wavelength-conversion material may absorb at least a portion oflight emitted from at least one the bare-die light-emitting diode andemit converted light having a different wavelength, converted light andunconverted light emitted by the at least one bare-die light-emittingdiode combining to form substantially white light. The substantiallywhite light may have a correlated color temperature in the range of 2000K to 10,000 K. A reflecting layer may be formed between at least aportion of the binder and the ACA. The reflecting layer may include orconsist essentially of a reflecting film and/or a plurality of particles(e.g., reflective particles). At least a portion of a surface of thebinder may have a texture having heights above the surface selected fromthe range of about 0.25 μm to about 15 μm. The ACA may include orconsist essentially of an anisotropic conductive film disposed on thebinder and the contacts. The composite wafer may be removed from themold substrate.

In yet another aspect, embodiments of the invention feature a method forforming a composite wafer including or consisting essentially of aplurality of discrete semiconductor dies suspended in a cured binder.The discrete semiconductor dies are disposed on a mold substrate. Eachsemiconductor die has at least two spaced-apart contacts, and at leastsome of the semiconductor dies are light-emitting diodes (e.g., bare-dielight-emitting diodes). The semiconductor dies are coated with a binder,and the binder is cured to form the composite wafer. At least a portionof the binder proximate the contacts is removed to expose at leastportions of the contacts. An ACA is applied over at least a portion ofthe binder and in contact with the contacts. The composite wafer isremoved from the mold substrate.

Embodiments of the invention may include one or more of the following inany of a variety of combinations. The ACA may include or consistessentially of an anisotropic conductive film. The ACA may be appliedover substantially the entire composite wafer. The ACA may be appliedover all of the contacts of the composite wafer but not a portion of thebinder.

In a further aspect, embodiments of the invention feature a compositewafer including or consisting essentially of a solid volume of apolymeric binder having a first surface and a second surface oppositethe first surface, a plurality of semiconductor dies suspended withinthe binder, and an ACA. The semiconductor dies each have a first face, asecond face opposite the first face, and at least one sidewall spanningthe first and second faces. At least two spaced-apart contacts aredisposed on the first face of each semiconductor die. Each contact has aterminal end protruding from the first surface and not covered by thebinder. The ACA is disposed over and in contact with the terminal endsof the contacts. At least some of the semiconductor dies are bare-dielight-emitting diodes. At least a portion of the binder is transparentto a wavelength of light emitted by the light-emitting diodes. Thebinder includes a wavelength-conversion material therein. At least aportion of the ACA opposite the contacts is available for electricalconnection.

Embodiments of the invention may include one or more of the following inany of a variety of combinations. The ACA may be disposed oversubstantially the entire composite wafer. The ACA may be disposed overthe terminal ends of all of the contacts but not a portion of thebinder. The ACA may include or consist essentially of an anisotropicconductive film disposed on the binder and the contacts. At leastportions of the contacts may protrude from the binder. Only a portion ofeach said sidewall may protrude from the binder. Thewavelength-conversion material may include or consist essentially of aphosphor and/or quantum dots. At least one light-emitting diode mayinclude or consist essentially of a semiconductor material including orconsisting essentially of GaAs, AlAs, InAs, GaP, AlP, InP, ZnO, CdSe,CdTe, ZnTe, GaN, AlN, InN, silicon, and/or an alloy or mixture thereof.The wavelength-conversion material may absorb at least a portion oflight emitted from at least one bare-die light-emitting diode and emitconverted light having a different wavelength, converted light andunconverted light emitted by the at least one bare-die light-emittingdiode combining to form substantially white light. The substantiallywhite light may have a correlated color temperature in the range of 2000K to 10,000 K. A reflecting layer may be disposed between at least aportion of the binder and the ACA. The reflecting layer may include orconsist essentially of a reflecting film and/or a plurality ofparticles. At least a portion of a surface of the binder may have atexture having heights above the surface selected from the range ofabout 0.25 μm to about 15 μm.

These and other objects, along with advantages and features of theinvention, will become more apparent through reference to the followingdescription, the accompanying drawings, and the claims. Furthermore, itis to be understood that the features of the various embodimentsdescribed herein are not mutually exclusive and can exist in variouscombinations and permutations. Reference throughout this specificationto “one example,” “an example,” “one embodiment,” or “an embodiment”means that a particular feature, structure, or characteristic describedin connection with the example is included in at least one example ofthe present technology. Thus, the occurrences of the phrases “in oneexample,” “in an example,” “one embodiment,” or “an embodiment” invarious places throughout this specification are not necessarily allreferring to the same example. Furthermore, the particular features,structures, routines, steps, or characteristics may be combined in anysuitable manner in one or more examples of the technology. The term“light” broadly connotes any wavelength or wavelength band in theelectromagnetic spectrum, including, without limitation, visible light,ultraviolet radiation, and infrared radiation. Similarly, photometricterms such as “illuminance,” “luminous flux,” and “luminous intensity”extend to and include their radiometric equivalents, such as“irradiance,” “radiant flux,” and “radiant intensity.” As used herein,the terms “substantially,” “approximately,” and “about” mean±10%, and insome embodiments, ±5%. The term “consists essentially of” meansexcluding other materials that contribute to function, unless otherwisedefined herein. Nonetheless, such other materials may be present,collectively or individually, in trace amounts.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, like reference characters generally refer to the sameparts throughout the different views. Also, the drawings are notnecessarily to scale, emphasis instead generally being placed uponillustrating the principles of the invention. In the followingdescription, various embodiments of the present invention are describedwith reference to the following drawings, in which:

FIG. 1 is a plan-view schematic of a semiconductor wafer composed ofunsingulated chips;

FIGS. 2A-2G are cross-sectional schematics of coated dies in accordancewith various embodiments of the invention;

FIGS. 3A and 3B are flowcharts for techniques of fabricating structuresin accordance with various embodiments of the invention;

FIGS. 4A-4G are cross-sectional schematics of process steps utilized tofabricate coated dies in accordance with various embodiments of theinvention;

FIG. 5 is a cross-sectional schematic of a coated die in accordance withvarious embodiments of the invention;

FIGS. 6A-6G are cross-sectional schematics of process steps utilized tofabricate coated dies in accordance with various embodiments of theinvention;

FIG. 7A is a cross-sectional schematic of device structures on asubstrate patterned to control die relief of coated dies incorporatingthe light-emitting elements in accordance with various embodiments ofthe invention;

FIG. 7B is a cross-sectional schematic of device structures on asubstrate with a mask to control die relief of coated dies incorporatingthe light-emitting elements in accordance with various embodiments ofthe invention;

FIGS. 8A-8D are cross-sectional schematics of device structures on asubstrate showing techniques of controlling die relief of coated diesincorporating light-emitting elements in accordance with variousembodiments of the invention;

FIGS. 9A and 9B are cross-sectional schematics of device structures on asubstrate in accordance with various embodiments of the invention;

FIG. 9C is a plan-view schematic of a lighting system utilizing coateddies in accordance with various embodiments of the invention;

FIGS. 10A-10D are cross-sectional schematics of process steps utilizedto fabricate coated dies in accordance with various embodiments of theinvention;

FIGS. 11A-11F and 12A are cross-sectional schematics of devicestructures in accordance with various embodiments of the invention;

FIGS. 12B and 12C are plan-view schematics of device structures inaccordance with various embodiments of the invention;

FIGS. 13A and 13B are cross-sectional schematics of device structures inaccordance with various embodiments of the invention;

FIGS. 14A and 14B are, respectively, a cross-sectional schematic and aplan-view schematic of a light-emitting element utilized in coated diesin accordance with various embodiments of the invention;

FIGS. 15 and 16 are cross-sectional schematics of light-emittingstructures in accordance with various embodiments of the invention;

FIGS. 17A-17C are cross-sectional schematics of coated diesincorporating optical elements in accordance with various embodiments ofthe invention;

FIG. 18 is a cross-sectional schematic of an intermediate structureformed during the fabrication of the coated die of FIG. 17A inaccordance with various embodiments of the invention;

FIG. 19A is a cross-sectional schematic of a coated die in accordancewith various embodiments of the invention;

FIG. 19B is a graph showing light output power as a function ofreflectance, in accordance with various embodiments of the invention;

FIGS. 20A-20C are cross-sectional schematics depicting a processutilized to fabricate structures in accordance with various embodimentsof the invention;

FIGS. 21A and 21B are cross-sectional schematics of structuresincorporating reflective particles in accordance with variousembodiments of the invention;

FIGS. 22A, 22B, 23A, 23B, 23D, 24A, 24B, and 25A-25E are cross-sectionalschematics depicting a process utilized to fabricate structures inaccordance with various embodiments of the invention;

FIG. 23C is a plan-view schematic of the structure depicted in FIG. 23B;

FIGS. 25F, 25G, and 26A-26D are cross-sectional schematics of electronicdevices in accordance with various embodiments of the invention;

FIGS. 27A-27C are cross-sectional schematics depicting a processutilized to fabricate structures in accordance with various embodimentsof the invention;

FIGS. 28A-28E are cross-sectional schematics of electronic devices inaccordance with various embodiments of the invention; and

FIGS. 29 and 30 are cross-sectional schematics of packaged systemsincorporating multiple devices in accordance with various embodiments ofthe invention.

DETAILED DESCRIPTION

Embodiments of the present invention provide a new approach toencapsulation and die attach of semiconductor chips (or “dies”). Inparticular, embodiments of the present invention provide a new approachto integration of phosphors and light-emitting elements (LEEs), such asLED dies, that addresses a number of the deficiencies and difficultiespresent in the current manufacture of packaged LEDs, for examplepackaged LEDs that emit white light (or “white LEDs”). Advantageously,the encapsulation (in the case of an LEE the encapsulant may include orconsist essentially of phosphor and a binder) and means for electricalcoupling of the contacts on the die to conductive traces on a mountingsurface may be integrated with the die at the wafer level, before it issingulated and mounted, for example on a circuit board or substrate, orplaced in a package. Alternatively, instead of being conventionallypackaged, embodiments of the invention produce a package-free white die.

The encapsulation is generally performed in a batch process (i.e., formultiple dies, even an entire wafer of dies, concurrently), resulting inrelatively low cost and improved uniformity and reproducibility. Forexample, the enablement of electrical coupling using an ACA may beperformed in a batch process, resulting in relatively low cost and asimplified process.

An example of an encapsulated structure is depicted as structure 200 inFIG. 2A. In one embodiment, structure 200 is a light-emitting structureand includes one or more LEEs 210, each of which features at least onecontact 220. As shown, the LEE 210 is partially surrounded by a phosphor230. At least a portion of one or more contacts 220 is not covered byphosphor 230. In the configuration shown in FIG. 2A, LEE 210 featurestwo contacts 220 that are situated on the same face or side 240 of LEE210 and are covered or partially covered with ACA 292. In someembodiments, ACA 292 may include or consist essentially of an epoxy oradhesive matrix component 225 and a plurality of conductive particles226 within the matrix 225. As shown, at least a portion of the ACA 292is not covered by phosphor 230 and is available for electricalconnection. Herein, “available for electrical connection” means thecontact or structure or material has sufficient free area to permitattachment to, e.g., a conductive trace, a circuit board, etc., and“free” means lacking any electrical connection (and in preferredembodiments, any mechanical connection) thereto. In one embodiment, ACA292 covers all or substantially all of the bottom of structure 200, asshown for example in FIG. 2A. In one embodiment, ACA 292 covers only allor substantially all of the face of LEE 210 having contacts 220, asshown for example in FIG. 2B. In one embodiment, surface 240 of LEE 210is coplanar or substantially coplanar with a surface 296 of phosphor230, as shown, for example, in FIGS. 2A and 2B, while in otherembodiments, surface 240 of LEE 210 is protrudes below surface 296 ofphosphor 230, as shown for example in FIGS. 2C, 2E, and 2F. In someembodiments, surface 240 of LEE 210 is above surface 296 of phosphor230, as shown for example in FIG. 2G. In some embodiments, all orportions of contacts 220 and/or all or portions of LEE 210 are embeddedin a portion of ACA 292, as shown for example in FIGS. 2A, 2B, 2C, 2F,and 2G. In some embodiments, ACA 292 is overlaid on all or portions ofcontacts 220 and/or all or portions of LEE 210, as shown for example inFIGS. 2D and 2E. In some embodiments (not shown) only a portion ofcontacts 220 are embedded in a portion of ACA 292. The coverage of ACA292 over LEE 210 and/or phosphor 230 are not limitations of the presentinvention. Whether all or a portion of contacts 220 and/or a portion ofLEE 210 are embedded in ACA 292 is not a limitation of the presentinvention. Whether all or a portion of contacts 220 are recessed withinor protrude from phosphor 230 is not a limitation of the presentinvention. However, in preferred embodiments of the invention, at leasta portion of contacts 220 are contactable to ACA 292 for subsequentelectrical connection therethrough.

In some embodiments, a portion of the body of LEE 210 is not coveredwith phosphor, as shown in FIG. 2C. FIG. 2C shows a structure similar tothat shown in FIG. 2A, but with a portion of the sidewall of the body ofLEE 210 not covered in phosphor. The extent that LEE 210 extends beyondthe edge of phosphor 230 may be identified as a “die relief” 297. Insome embodiments, the die relief is positive, as shown in FIG. 2C, butin other embodiments the die relief may be substantially zero, as shownin FIG. 2A or even negative, as shown in FIG. 2G. Another dimension thatmay be advantageously controlled is a “contact relief” 298, as shown inFIG. 2C. The contact relief 298 is the amount that the contact protrudesfrom the adjacent surface of the phosphor. In some embodiments, thecontact relief may be positive, while in other embodiments it may besubstantially zero or negative. In some embodiments, the die relief maybe in the range of 0 to about 30 μm. In some embodiments, the die reliefmay be substantially zero and the contact relief is positive. In someembodiments, both the die and contact relief are positive. In someembodiments, the contact relief is in the range of about 0 to about 30μm. In some embodiments, the contact relief is positive and in the rangeof about 1 μm to about 8 μm. While the polarities and absolute valuesfor the die and contact relief are not a limitation of the presentinvention, one aspect of preferred embodiments of the invention is thatACA 292 is contactable to contacts 220, as mentioned above. In someembodiments, this means that contacts 220 are in physical contact withACA 292 before curing of ACA 292 (as will be described herein). In someembodiments, this means that contacts 220 are brought into contact withACA 292 during processing, for example during the ACA cure process. Inall aspects this means that contacts 220 are positioned such that aftercuring, they are able to make electrical contact through ACA 292 to anunderlying substrate or carrier.

In some embodiments, phosphor 230 absorbs a portion of light emitted byLEE 210 and re-emits it at one or more different wavelengths, and thecombination of light emitted by LEE 210 and phosphor 230 define one ormore optical characteristics of structure 200, for example colortemperature, color rendering index (CRI), or the like. In someembodiments, it is advantageous to control the die and contact reliefsuch that multiple structures 200 have the same or substantially thesame optical characteristics. If the die relief is relatively large,then a larger proportion of light emitted by LEE 210 may be observeddirectly, without passing through phosphor 230; thus, in someembodiments, a relatively small positive die relief is advantageousbecause it reduces the amount of light emitted directly from LEE 210that does not pass through phosphor 230. In some embodiments, thecontact relief is at least the height of contacts 220, that is, thedistance that contacts 220 protrude from the surrounding surface of LEE210. In some embodiments, the die relief may be in the range of about 0to about 30 μm, while in other embodiments, the die relief may be in therange of about 0 to 10 μm. In some embodiments, the die relief is lessthan 20% of the height (i.e., the dimension perpendicular to the face ofthe die from which the contacts protrude) of LEE 210, while in otherembodiments, the die relief is less than 10% or even less than 5% of theheight of LEE 210. In some embodiments, the die relief is less thanabout 20% of the height of LEE 210, while in other embodiments, the dierelief is less than about 10% or even less than about 5% or less thanabout 1% of the height of LEE 210. In some embodiments, it may beadvantageous to reduce the variation in die relief within a wafer ofcoated dies (also referred to herein as a “white wafer” or “white diewafer”) and/or between white wafers because it reduces the variation inone or more optical characteristics of the white dies. In someembodiments, the variation in die relief is less than about 25%, or lessthan about 10%, or less than about 5%, or even less than about 1%.

In some embodiments, the die relief and contact relief values arerelated. For example, in the embodiment shown in FIG. 2C, the contactrelief is approximately determined by the sum of the die relief and theheight of the contact, where the contact height is the amount that thecontacts protrude from the surface of LEE 210. In some embodiments, thecontact relief and/or die relief may be determined or optimized andcontrolled to minimize the amount of light emitted by LEE 210 that doesnot pass through phosphor 230 while providing sufficient contact and/ordie relief to produce a reliable and robust electrical contact to LEEcontacts 220 through ACA 292, as well as to produce a reliable androbust mechanical attachment of the structure 200, for example to anunderlying substrate or circuit board.

While face 240 of LEE 210 is shown as being a single planar surface,this is not a limitation of the present invention, and in otherembodiments, face 240 is composed of multiple non-coplanar surfaces ormay have other configurations. In some embodiments, LEE 210 has morethan two contacts 220. Structures 200 are shown in FIGS. 2A-2G as havingno phosphor 230 covering face 240; however, this is not a limitation ofthe present invention, and in other embodiments phosphor 230 covers atleast a portion of face 240. As discussed herein, phosphor may refer toa binder or matrix material alone or a mixture of the binder andwavelength-conversion material. In FIG. 2A, the width of phosphor 230around the sides of LEE 210 is identified as a width 250, while thethickness of phosphor 230 over LEE 210 is identified as a thickness 260and the thickness of phosphor 230 adjacent to LEE 210 is identified as athickness 270. FIGS. 2A-2G show width 250, thickness 260, and thickness270 as substantially constant; however, this is not a limitation of thepresent invention, and in other embodiments width 250, thickness 260,and/or thickness 270 may vary.

FIGS. 2A-2G show structures 200 each including one LEE 210; however,this is not a limitation of the present invention, and in otherembodiments structure 200 includes more than one LEE 210. In someembodiments, multiple LEEs 210 of a single structure 200 are all thesame, while in other embodiments a structure 200 includes at least twodifferent types of LEEs 210. In one embodiment, different types of LEEs210 emit light at different wavelengths. For example, structure 200 mayinclude one or more of each of three different types of LEEs 210, whereat least one type emits in the blue wavelength range, at least one emitsin the green wavelength range, and at least one emits in the redwavelength range. In one embodiment, structure 200 may include one ormore of each of two different types of LEEs 210, where at least one typeemits in the blue wavelength range and at least one emits in the redwavelength range. The specific configuration of the LEEs 210 instructure 200 as well as their operating characteristics and propertiesare not limitations of the present invention. In one embodiment,different types of LEEs 210 have different light output powers. In oneembodiment, phosphor 230 may be composed of multiple portions orvolumes, where each portion or volume includes or consists essentiallyof one or more phosphors different from one or more phosphors in anotherportion. In one embodiment of this example, one or more portions includeor consist essentially of only a transparent binder material, while oneor more other portions include or consist essentially of a binder andone or more phosphors.

In some embodiments, a surface 280 of phosphor 230 is parallel orsubstantially parallel to a surface 242 of LEE 210. In some embodiments,a surface 290 of phosphor 230 is parallel or substantially parallel to asurface 244 of LEE 210. In some embodiments, phosphor 230 forms asubstantially cubic or rectangular-solid shape (the contour of which maybe broken by portions of the LEE 210 and/or the contacts of the LEE210). The thickness 260 of phosphor 230 over LEE 210 is shown as thesame or substantially the same over the entirety of LEE 210; however,this is not a limitation of the present invention, and in otherembodiments thickness 260 of phosphor 230 over LEE 210 varies. Thethickness 270 of phosphor 230 adjacent to LEE 210 is shown as the sameor substantially the same for structure 200; however, this is not alimitation of the present invention, and in other embodiments thickness270 of phosphor 230 adjacent to LEE 210 varies. FIGS. 2A and 2C showsurface 280 and side surfaces 290 of phosphor 230 as flat orsubstantially flat; however, this is not a limitation of the presentinvention, and in other embodiments surface 280 and/or surface 290 arecurved, roughened, patterned, or textured in a regular, periodic, orrandom pattern. In some embodiments, phosphor 230 has, at least in part,a smooth, substantially continuous shape. In some embodiments, shapingand/or patterning or texturing of the surface is achieved during theformation or molding process, while in other embodiments shaping and/orpatterning or texturing is performed after the phosphor is molded orafter it is cured or partially cured.

LEE 210 in FIG. 2A is shown as rectangular in cross-section, but this isnot a limitation of the present invention, and in other embodiments LEE210 is square, hexagonal, circular, triangular or any arbitrary shapeand/or may have sidewalls forming any angle with respect to the surface280 of white die 200. In FIG. 2A width 250 of phosphor 230 on the sidesof LEE 210 is shown as the same or substantially the same on all sidesof LEE 210; however, this is not a limitation of the present invention,and in other embodiments width 250 of phosphor 230 is different on oneor more or all sides of LEE 210. FIG. 2A shows width 250 of phosphor 230as the same or substantially the same across each side of LEE 210;however, this is not a limitation of the present invention, and in otherembodiments width 250 of phosphor 230 varies along one or more sides ofLEE 210.

As discussed above, embodiments of the present invention form phosphor230 and ACA 292 on LEE 210, preferably at a wafer level, prior toattachment (electrical and/or mechanical) to a package or to asubstrate. Structure 200 may then be integrated in a variety ofpackages, as discussed below. FIG. 3A shows a flow chart of a process300 for forming the structure of FIG. 2C. Process 300 is shown havingeight steps; however, this is not a limitation of the present invention,and in other embodiments the invention has more or fewer steps and/orthe steps may be performed in different order. In step 310, a firstsurface or base is provided. In step 320, one or more LEEs are placed orformed on the base. In step 330, the phosphor is provided. In step 340,the phosphor is formed over the LEE and base. In step 350, the phosphoris cured. In step 354 the cured or partially cured phosphor wafer orwhite die wafer is removed from the base. In step 355, the ACA is formedover or attached to the cured phosphor on the side containing theexposed or partially exposed contacts. In step 360, the phosphor-coatedstructure is singulated into white dies.

FIG. 3B shows a flow chart of a process 301 for forming the structure ofFIG. 2B. Process 301 is shown having nine steps; however, this is not alimitation of the present invention, and in other embodiments theinvention has more or fewer steps and/or the steps may be performed indifferent order. In step 315 a wafer or portion of a wafer of LEE diesis provided. This wafer is typically not singulated or partiallysingulated. In step 325, ACA is formed over or attached to the contactside of the wafer. In step 335, the wafer and ACA are singulated. Instep 310, a first surface or base is provided. In step 321, one or moreLEEs (along with the ACA) are placed or formed on the base. In step 330,the phosphor is provided. In step 340, the phosphor is formed over theLEE and base. In step 350, the phosphor is cured. In step 360, thestructure is singulated into white dies.

As will be discussed herein, embodiments of the invention may bepracticed with any type of device, die or chip, for example passiveelements, active elements, integrated circuits, light-emitting elementssuch as LEDs and lasers, light-absorbing elements such as detectors orsolar cells or combinations of any of these elements. The type, functionor quantity of elements is not a limitation of the present invention.

Various approaches to using white dies 200 are discussed herein. FIGS.4A-4G depict one embodiment of process 300. In this embodiment, a base410 is provided (step 310) and LEEs 210 are placed on or adhered to base410 (step 320) with contacts 220 adjacent to base 410 (FIG. 4A). Base410 may also be referred to as a “mold substrate.” In one embodiment,base 410 includes or consists essentially of an adhesive film or tape.In some embodiments, base 410 includes or consists essentially of amaterial which has a relatively low adhesion to phosphor 230, that is,it permits removal of cured phosphor 230 from base 410. In someembodiments, base 410 is the same as or similar to dicing or transfertapes used in the semiconductor industry for singulation and/or transferof dies, for example Revalpha from Nitto Denko Corporation or tapes fromSemiconductor Equipment Corporation. In some embodiments, base 410includes or consists essentially of a water-soluble material oradhesive, or it may be covered or be partially covered with awater-soluble material. For example, the adhesive of base 410 or theliner or both may be water soluble. In some embodiments, thewater-soluble material includes or consists essentially of awater-soluble tape, for example 3M type 5414.

In some embodiments, base 410 includes or consists essentially of amaterial with variable adhesive force. In such embodiments, the adhesiveforce may be altered after formation and curing of the phosphor to makeit easier to remove the white die or white die wafer from base 410. (Awhite die wafer, also referred to as a composite wafer, is hereindefined as a plurality of semiconductor dies suspended in a binder.) Inone embodiment, such a variable adhesive force material may be a thermalrelease tape or a UV release tape. In one embodiment, the variableadhesive force material may be a water-soluble tape. In one embodiment,the variable adhesive force material may be an electrostatic chuck (LEEs210 are formed or placed on the electrostatic chuck, similar to thestructure shown in FIG. 4A). In this embodiment, LEEs 210 are held inplace on the electrostatic chuck by electrostatic forces that may beactivated or deactivated electrically.

In some embodiments, it is desirable for all or a portion of the face ofcontact 220 to be exposed after formation of white die 200, that is, tonot be covered by phosphor 230. In some embodiments, placing or adheringall or a portion of the face of contact 220 adjacent to base 410prevents coverage or formation of phosphor 230 over all or a portion ofcontact 220 or over all or a portion of the face of contact 220. In someembodiments, the thickness, hardness and/or other properties of acoating on base 410, or the properties of base 410, for example anadhesive thickness, chemical composition, surface energy, hardness,elasticity, etc., may be varied to ensure the desired level of exposureof contacts 220, for example by proximity to base 410 or partial or fullembedding of contacts 220 into base 410.

In some embodiments, base 410 includes or consists essentially of asurface or a mold (e.g., a non-flat surface). In one embodiment,barriers 450 are formed by a recess in base 410. In FIG. 4B barriers 450are shown as perpendicular or substantially perpendicular to a bottomsurface 435; however, this is not a limitation of the present invention,and in other embodiments barriers 450 form any angle with surface 435.Base 410 may include or consist essentially of one or more of a varietyof materials, for example glass, PET, PEN, plastic film, tape, adhesiveon plastic film, metal, acrylic, polycarbonate, polymers, silicone,polytetrafluoroethylene (Teflon), or the like. In some embodiments, base410 is rigid or substantially rigid, while in others base 410 isflexible. In some embodiments, it is advantageous for base 410 toinclude or consist essentially of a “non-stick” material such as Teflon,or a fluorinated material such as Fluon ETFE produced by Asahi Glass orto include a non-stick coating over the surface or portion of thesurface that may come in contact with phosphor 230 (for example thebinder in phosphor 230) so that phosphor 230 does not stick to base 410.In some embodiments, base 410 includes or consists essentially of alayer of material on surface 435 and/or barriers 450 that does notadhere well to the binder material. In some embodiments, base 410includes or consists essentially of a water-soluble material oradhesive, or base 410 is partially or completely lined with awater-soluble material to aid in the release of base 410 from thematerial formed in base 410. In one embodiment, base 410 includes orconsists essentially of or is partially or fully lined with awater-soluble tape, for example 3M type 5414. In some embodiments, base410 is transparent to light, for example to visible or UV radiation. Insome embodiments, the height of barrier 450 ranges from about 10 μm toabout 1000 μm; however, the height of barrier 450 is not a limitation ofthe present invention, and in other embodiments barrier 450 has anyheight. In some embodiments, the area of base 410 is in the range ofabout 0.25 mm² to about 900 cm²; however, the area of base 410 is not alimitation of the present invention, and in other embodiments the areaof base 410 is smaller or larger. When barrier 450 is not a part of base410, barrier 450 may include or consist essentially of a materialsimilar to that or different from that of base 410. In some embodiments,barrier 450 may be a ring or stencil surrounding LEE 210.

A spacing 405 between adjacent LEEs 210, as shown in FIG. 4A, may beadjusted to control the width of phosphor 230 around the sides of LEEs210. In one embodiment, spacing 405 between LEEs 210 is approximatelydetermined by the sum of twice the desired sidewall thickness 250 of thephosphor and the kerf (where the kerf is the width of the region removedduring the singulation process of white dies 200, for example identifiedas kerf 480 in FIG. 4F). In other embodiments, as discussed herein, thespacing 405 is independent of the amount of phosphor 230 surroundingLEEs 210. The thickness of phosphor 230 over the LEEs 210 may becontrolled by controlling a thickness 425 of phosphor 420 that is formedor dispensed. In one embodiment, thickness 260 of phosphor 230 over LEE210 is given approximately by the thickness 425 less the thickness 445.

In some embodiments, the spacing 405 between LEEs 210 is in the range ofabout 0.10 mm to about 5 mm, or preferably in the range of about 0.2 mmto about 1.5 mm. In some embodiments, it is advantageous, in order toreduce cost, to reduce the spacing 405 between LEEs 210. In someembodiments, reducing spacing 405 between LEEs 210 permits themanufacture of more LEEs 210 per unit area, thus reducing themanufacturing cost. In some embodiments, it is advantageous, in order toreduce cost, to reduce the amount of phosphor 230 formed around each LEE210. In some embodiments, this reduces the volume and thus the cost ofthe binder associated with each LEE 210.

The next step (step 330) in process 300 provides a phosphor (uncured orpartially cured phosphor 420). In one embodiment, phosphor 420 includesor consists essentially of a phosphor and a binder. In some embodiments,the phosphor and binder are mixed prior to application, for example in acentrifugal mixer, with or without a partial vacuum over the mixture.

In the next step (step 340) in process 300, phosphor 420 is formed overbase 410 and LEEs 210 as shown in FIG. 4B. In some embodiments, phosphor420 is contained or bounded by surface 435 of base 410 and optionalsides or barriers 450 as shown in FIG. 4B. In this example, phosphor 420has a bottom surface or face 460 and a top surface or face 440. In someembodiments, surfaces 460 and 440 are substantially parallel to eachother. In some embodiments, surfaces 460 and 440 are substantially flatand parallel.

Phosphor 420 may be formed by a variety of techniques, for examplecasting, dispensing, pouring, injecting, injection, compression,transfer or other forms of molding, Mayer bar or draw-down bar, doctorblade, etc. The method of formation of phosphor 420 is not a limitationof the present invention. In some embodiments, base 410 is positionedsuch that surface 435 is level, such that when phosphor 420 is formed onbase 410, surface 435, bottom surface 460 of phosphor 420 and topsurface 440 of phosphor 420 are parallel or substantially parallel,forming a thin layer of phosphor 420 that has a uniform or substantiallyuniform thickness across all or most of the area of phosphor 420. Insome embodiments, one or more barriers 450 are used to prevent orpartially prevent the spread of phosphor 420. In some embodiments,surface 435 and barriers 450 form a mold for phosphor 420. In someembodiments, barriers 450 are portions of a separate component placedover base 410 surrounding LEEs 210. In some embodiments, barriers 450are not used. Some embodiments of the present invention utilize a levelbase 410 and gravity to automatically produce phosphor layer 420 with auniform or substantially uniform thickness. In one embodiment, thethickness uniformity of phosphor 420 is within about ±15%, within about±10%, within about ±5%, or within about ±1% or less. In one embodiment,phosphor 420 has a thickness in the range of about 5 μm to about 2000μm, while in other embodiments the phosphor has a thickness in the rangeof about 50 μm to about 500 μm. In some embodiments, phosphor 420includes or consists essentially of a phosphor and a binder, and it maybe desirable to adjust the concentration of the phosphor to permit thebinder thickness to be relatively low, for example less than about 500μm, or less than about 300 μm, or less than about 200 μm, in order toreduce the total volume of binder used and thus reduce the cost of thebinder.

In one embodiment, the time between mixing phosphor 420 including orconsisting essentially of binder and phosphor powder and formingphosphor 420 over base 410 is relatively short compared to the timerequired for settling of the powder in the binder, such that thephosphor and binder form a uniform and homogeneously distributed orsubstantially uniform and homogeneously distributed combination ofphosphor powder in the binder. In one embodiment, the compositionaluniformity of phosphor 420, that is the distribution of phosphor powderin the binder, is uniform to within about ±15%, within about ±10%,within about ±5% or within about ±1%. In some mixtures of phosphor andpowder, settling starts to occur within about 10 to about 30 minutes,while formation of phosphor 420 in over base 410 occurs within about0.25 minute to about 5 minutes. In some embodiments, the structure shownin FIG. 4B is exposed to a partial vacuum to degas, i.e., remove all ora portion of any dissolved gases in phosphor 420, to reduce or eliminatethe number of bubbles in phosphor 420. In some embodiments, phosphor 420is exposed to a partial vacuum before formation on base 410. In someembodiments, phosphor 420 is formed over base 410 in a partial vacuum.In some embodiments of the present invention, base 410 is not level,resulting in phosphor 420 having a non-uniform thickness over base 410and LEE 210, as discussed herein in more detail.

Phosphor 420 is then cured, or partially cured producing cured phosphor230 (step 350) as shown in FIG. 4C. Curing may include or consistessentially of heating, exposure to radiation of various sources, forexample visible, UV and/or IR light, or chemical curing (i.e.,introduction of a chemical agent that promotes cross-linking of thephosphor binder). In one embodiment, phosphor 420 is cured by UV orother radiation. In one embodiment, base 410 is held within the curingequipment prior to or just after step 350 of FIG. 3. In some mixtures ofbinder and powder, settling starts to occur within about 10 to about 30minutes, while curing of phosphor 420 over base 410 occurs within about0.10 minute to about 5 minutes. In one embodiment, steps 340 and 350 maytake less than about 30 minutes, less than about 10 minutes, less thanabout 5 minutes, or less than about 1 minute. In some embodiments, thecuring step 350 includes or consists essentially of multiple sub-curingsteps. For example, a first sub-curing step may be performed to “freeze”the phosphor particles in the matrix, and this may be followed by asecond sub-curing step to fully cure the binder. In some embodiments,both the formation and curing process may occur within about 0.25 minuteto about 7 minutes. In some embodiments, both the formation and curingprocess may take less than about 4 minutes.

In step 343 of process 300, the cured or partially cured phosphor wafer,also referred to as a white wafer, is removed from base 410, as shown inFIG. 4D. The structure in FIG. 4D includes phosphor 230 and LEEs 210,with at least a portion of some or all of contacts 220 not covered byphosphor 230. The details of any die and contact relief are not shown inFIGS. 4A-4G and FIG. 5, for clarity purposes.

In step 355 of process 300, ACA 292 is applied to the cured or partiallycured structure of FIG. 4D. ACA 292 is applied to the side or portion ofthe structure including the exposed or partially exposed contacts 220 asshown in FIG. 4E. The structure shown in FIG. 4E (not including optionalprotective layer 437) may be referred to as an ACA white die wafer orACA white wafer or ACA composite wafer. Conductive particles 226 mayinclude or consist essentially of Au, Ni, or Ni- and Au-covered polymerparticles, or Au, Ni, or Ni- and Au-covered polymer particles that arecoated with an insulating layer. The specific configuration andmaterials of the ACA (which may also be in the form of a film whenapplied, i.e., an anisotropic conductive film (ACF)), and which may bepressure-activated, are not a limitation of the present invention. (Asutilized herein, an ACF is a film having a predefined and substantiallyconstant thickness when applied to contacts or other structures, ratherthan an adhesive in liquid and/or flowable form.) The application of ACA292 to the white wafer may be achieved by dispensing, casting, spraying,use of a doctor blade, or a meniscus process using an ACA solution.Alternatively, an ACF may be employed, in which case the film may beadhered or laminated to the white wafer. The thickness of the ACF may bein the range of about 5 μm to about 50 μm or larger. In one embodiment,the ACA or ACF is heated and pressed against or laminated to the whitewafer to attach ACA or ACF 292 to the white wafer. In some embodiments,a release film is applied over ACF or ACA 292 or over optionalprotective layer 437 prior to heating and pressing or lamination, toprevent adhesion of ACA or ACF 210 or optional protective layer 437 tothe heating, pressing, or lamination apparatus. While subsequentreferences to ACF 292 will be referred to as ACA 292 herein forconvenience, it should be understood that ACA 292 may include or consistessentially of an ACF unless otherwise indicated. In some embodiments,ACA 292 is attached to the phosphor wafer without or substantiallywithout the formation of voids between the phosphor wafer and ACA 292;however, this is not a limitation of the present invention, and in otherembodiments voids may be present between the phosphor wafer and ACA 292.In some embodiments, the heating and application of pressure areperformed in a partial vacuum. In one embodiment, the ACA 292 ispartially cured on the wafer during this process. In some embodiments,the ACA 202 resin is in a semi-cured state at this point in the process,for example about 50% cured or less. In some embodiments, phosphor 420is partially cured, after which ACA 292 is applied, followed by one ormore additional curing steps. In some embodiments, an optionalprotective layer 437 is formed over ACA layer 292 (on the side oppositeLEEs 210) to protect ACA 292 during portions of the process. Theoptional protective layer is removed before attachment to the mountingsubstrate.

After formation of ACA 292, the structure shown in FIG. 4E issingulated, as shown in FIG. 4F. Separation, or singulation, of phosphor230 to form structure 200 may be performed by a variety of techniques,for example laser cutting, cutting with a knife, die cutting, dicing,saw cutting, water jet cutting, ablation, or the like. In someembodiments, the ACA white wafer is mounted on a temporary substrate 430for the singulation process, as shown in FIG. 4F. The method ofsingulation is not a limitation of the present invention. Thesingulation process results in separation into individual structures200, where each structure 200 features at least one LEE 210, a portionof ACA 292 and a portion of phosphor 230, as shown in FIG. 2A.Singulation takes place between LEEs 210; thus, in some embodiments itis necessary to be able to align the singulation tool with the spaces,also called streets, between LEEs 210. In some embodiments, the ACAwhite wafer is mounted on a temporary substrate 430 with the contactsup, to permit relatively straightforward alignment of the singulationtool with LEE 210, to permit accurate singulation. In some embodiments,ACA 292 is transparent or partially transparent so that the positions ofthe singulation cuts are between LEEs 210. FIGS. 2A and 4F show one LEE210 per singulation unit; however, this is not a limitation of thepresent invention, and in other embodiments one or more singulationunits include multiple LEEs 210. In other embodiments, ACA 292 is opaqueor translucent and alignment of the singulation tool with the streetsmay be accomplished by other techniques, for example using alignmentmarks, fiducials, etc. The method of alignment of the singulation toolto the streets is not a limitation of the present invention. Anotheraspect of this process is the adhesion of ACA 292 to phosphor 230 andLEE 210. ACA 292 generally has sufficient adhesion to phosphor 230 andLEE 210 such that singulation does not cause delamination or partialdelamination of ACA 210 from phosphor 230 or LEE 210.

In some embodiments, the spacing between structures 200 aftersingulation is at least partially determined by the kerf of thesingulation process. In some embodiments, it may be advantageous toincrease the spacing between structures 200 for a subsequent step in theprocess, for example the pick-and-place operation to attach thestructures 200 to a substrate. In some embodiments, increasing thespacing is accomplished by using a temporary substrate 430 that isexpandable, for example an expandable dicing tape, for example Tape18733 from Semiconductor Equipment Corporation, using a die expandertool, for example a model 1810 die matrix expander manufactured bySemiconductor Equipment Corporation. The expandable tape is stretched,for example using a die matrix expander tool, to increase the spacebetween structures 200.

In some embodiments, white dies 200 may have a size ranging from about0.15 mm to about 5 mm; however, the size of white dies 200 is not alimitation of the present invention. In some embodiments, the thicknessof phosphor 230 surrounding LEEs 210 may be substantially the same, fordifferent size LEEs 210. In some embodiments, the size of white die 200may be increased by the incorporation of multiple LEEs 210. In someembodiments, the size of white die 200 including multiple LEEs 210 isdetermined by the size and number of LEEs 210 and the thickness ofphosphor 230 surrounding each LEE 210, and in some embodiments thethickness of phosphor 230 surrounding each LEE 210 in a multiple LEE 210white die 200 may be substantially the same as the thickness of phosphor230 surrounding a single LEE 210 white die 200. For example, a white dieincluding a large array of LEEs 210 may have a lateral dimension of atleast 3 mm, or at least 7 mm, or at least 25 mm. For some white dies200, separation may be optional, for example in the case of large arraysof LEEs 210. Separation of phosphor 230 may be performed by a variety oftechniques, for example laser cutting, cutting with a knife, diecutting, dicing, saw cutting, water jet cutting, ablation, or the like.In some embodiments, the kerf may be below about 200 μm or below about100 μm or below about 50 μm or even below 25 μm. In some embodiments,the smaller the kerf, the larger number of white dies 200 that may bemanufactured in a unit area—thus, decreasing the kerf typically resultsin a reduction in cost. This permits very large arrays of white dies 200to be formed in a relatively small area with relatively high throughputand relatively low cost.

In preferred embodiments, the process to form the phosphor over andaround the LEE is controlled to produce a relatively repeatable anduniform phosphor thickness, resulting in uniform opticalcharacteristics. The ability to form a very large number of white dies200 from a relatively small area of phosphor, in a relatively shorttime, to avoid or minimize settling of the phosphor powder in thebinder, coupled with the relatively high thickness uniformity, leads tovery large arrays of white dies 200 having relatively narrowdistribution of optical characteristics, such as chromaticity, colortemperature, color rendering index (CRI), luminous flux, etc. and verylow manufacture cost. In one embodiment, an entire wafer of LEEs 210 maybe batch processed simultaneously using this approach. For example insome embodiments LEEs 210 may be produced in wafer form, for example ona 2″ or 4″ or 6″ or 8″ diameter wafer. After LEEs 210 are fabricated andsingulated (here singulation refers to singulation of the wafer on whichLEEs 210 are formed), they may be transferred to mold substrate 410 forthe white die process detailed herein. In some embodiments, the entirewafer of LEEs 210 may be transferred in batch mode (i.e., together) tomold substrate 410. In other embodiments, LEEs 210 may be transferred tomold substrate 410 die-by-die or in groups of dies.

In some embodiments, phosphor 230 includes or consists essentially ofonly a transparent binder that is transparent to a wavelength of lightemitted by LEEs 210.

In some embodiments, the structure shown in FIG. 4F may be transferredto another substrate 411 such that contacts 220 are accessible, as shownin FIG. 4G. Such a transfer may be performed using transfer tape, apick-and-place tool with a die flipper or any other technique. In someembodiments, this transfer may be done in batch mode (i.e., all dies atonce), while in other embodiments it may be done die-by-die or forgroups of dies. In some embodiments, the transfer may be performedbefore singulation of the white die wafer.

The result of this process is a white die 200, as shown in FIG. 2A. Theprocess provides a batch method to produce dies integrated with phosphorand ACA, with uniform phosphor over each die, in a cost-effective way,before the dies are placed or integrated into any kind of package oronto a circuit board.

White dies 200 may then be removed from base 411 or 430 for placement ina package or on a substrate or circuit board. In some embodiments, whitedies 200 may be used as is, without a package, for example by mountingon a flexible or rigid circuit or wiring board or in other lighting ofillumination systems. In some embodiments, white dies 200 may be removedfrom base 411 or 430 and have ACA 292 available for electricalconnection, as shown in, for example FIG. 2A.

In one embodiment, only one phosphor 420 is used; however, this is not alimitation of the present invention, and in other embodiments multiplephosphors are used. In one embodiment, phosphor 420 may include orconsist essentially of multiple different phosphor powders in a binder.In one embodiment, a first phosphor 420 is deposited and cured orpartially cured, followed by the deposition and curing of one or moresuccessive phosphors. In one embodiment, a binder is deposited and curedor partially cured, and the binder is transparent to a wavelength oflight emitted by LEE 210 and/or phosphor 420 or 230, followed by thedeposition and curing of one or more phosphor 420, to form a layeredstructure in which one or more layers have a phosphor composition, typeand/or thickness different from each other. In this way, aremote-phosphor white die 400 may be fabricated, as shown in FIG. 5.FIG. 5 shows one embodiment of a remote phosphor white die 500, in whichphosphor 230 is spatially separated from LEE 210 by a transparent binderor matrix material 510. In such a structure, the extent of the overhangof the phosphor containing layer(s) 230 past the edges of LEE 210 may bevaried to optimize the amount of light from LEE 210 that is absorbed byphosphor 230. Such an approach may also be used to form multiple layersof phosphor and/or transparent binder 510 on LEE 210.

FIGS. 6A-6E depict one embodiment of process 301. In contrast to process300, process 301 forms or attaches the ACA 292 to all or a portion of anunsingulated or partially singulated wafer of LEEs. FIG. 6A shows awafer of unsingulated LEEs 210, identified as wafer 10, per step 315.FIG. 6B shows the structure of FIG. 6A at a later stage of manufacture,per step 325. In FIG. 6B, ACA 292 has been applied to the contact sideof wafer 10. FIG. 6C shows the structure of FIG. 6B at a later stage ofmanufacture. In FIG. 6C the structure has been optionally mounted onbase 610, with ACA 292 adjacent to base 610, and wafer 10 and ACA 292have been singulated, per step 335. Singulation may be performed by anyof a variety of techniques, for example scribing, sawing, dicing, lasercutting, water jet cutting, or the like. While FIG. 6C shows singulationoccurring with ACA 292 adjacent to base 610, this is not a limitation ofthe present invention, and in other embodiments singulation may occurwith the back side of wafer 10 adjacent to (and even contacting) base610.

In some embodiments, it may be advantageous to provide a liner orprotective layer to the outside surface of ACA 292 that faces away fromthe LEE 210. The protective layer may be a film, such as a mold releasefilm, or another material such as PET. A property of the protectivelayer is that it does not itself include an adhesive material on theside facing the ACA 292. The protective layer is adjacent to base 610during singulation step 335. In some embodiments, the protective layeris fully singulated during step 335. In other embodiments, for examplein an embodiment where the protective layer includes an expandablematerial, the protective layer is optionally not singulated or is onlypartially singulated during step 335. For example the depth of the cutmade by the singulation process may optionally extend only partiallythrough the thickness of the protective layer.

In some embodiments, it may be advantageous to at least partially curethe ACA prior to performing step 335. In other embodiments, it might beadvantageous to partially cure the ACA, or further cure the ACApartially, prior to molding.

In some embodiments, it may be advantageous to increase the spacingbetween LEEs 210 prior to molding. In some embodiments, increasing thespacing is accomplished by using a temporary substrate that isexpandable, for example an expandable dicing tape, for example Tape18733 from Semiconductor Equipment Corporation, using a die expandertool, for example a model 1810 die matrix expander manufactured bySemiconductor Equipment Corporation. In some embodiments the liner orprotective layer discussed above may be expandable. The expandable tapeis stretched, for example using a die matrix expander tool, to increasethe space between LEEs 210. In one embodiment, this may be done bytransferring the structures to a second base such that the pitch betweenLEEs on the second base is larger, for example using a pick-and-placetool. In step 310 a base is provided, and in step 321 the LEEs and ACAare formed or placed on the base. These steps may be accomplished byusing the singulation base (if present) or a different base. The type ofbase and whether the spacing is increased or not, or whether base 610 isused as a molding base or LEE 210 are transferred to another base, arenot limitations of the present invention. The mold base 611 as shown inFIG. 6D may be similar to other mold bases described herein and in someembodiments may be the same as singulation base 610.

As discussed herein with respect to step 330 (provide phosphor), step340 (form phosphor over LEEs and the base) and step 350 (cure phosphor),the steps described in process 301 may be performed in a similarfashion. FIG. 6E shows the structure of FIG. 6D after formation andcuring or partial curing of the phosphor. FIG. 6F shows the structure ofFIG. 6E at a later stage of manufacture. In this process it may bepreferable to choose an ACA that is not fully cured by the thermalbudget of the phosphor cure process. In FIG. 6F the structure of FIG. 6Ehas been separated or singulated, per step 360 of process 301.

As discussed herein, in some embodiments, the structure shown in FIG. 6Fmay be transferred to another substrate such that contacts 220 areelectrically accessible via ACA 292. Such a transfer may be performedusing transfer tape, a pick-and-place tool with a die flipper or anyother technique. In some embodiments, this transfer may be done in batchmode, while in other embodiments it may be done die-by-die or in groupsof dies. In some embodiments, the transfer may be performed beforesingulation of the white die wafer. The result of this process 301 is awhite die 200, as shown, for example, in FIG. 6G. The process provides abatch method to produce dies integrated with phosphor and ACA, withuniform phosphor over each die, in a cost-effective way, before the diesare placed or integrated into any kind of package or onto a circuitboard.

White dies 200 may then be removed from the substrate for placement in apackage or on a substrate or circuit board. In some embodiments, whitedies 200 may be used as is, without a package, for example by mountingon a flexible or rigid circuit or wiring board or in other lighting ofillumination systems. In some embodiments, white dies 200 may be removedfrom the temporary base and have ACA 292 available for electricalconnection, as shown in, for example FIG. 2B or 6G.

FIG. 6G shows the bottom surface of ACA 292 as coplanar or substantiallycoplanar with the bottom of phosphor 230; however, this is not alimitation of the present invention and in other embodiments ACA 292and/or all or a portion of contacts 220 and/or a portion of LEE 210 maybe proud of phosphor 230, as shown in FIG. 2B. In other words, the ACAand/or contact and/or die relief may be positive or negative. In oneembodiment, the structure of FIG. 2B may be achieved by using a moldsubstrate 710 having recesses 720 into which the LEEs 210 and ACA 292fit, as shown in FIG. 7A. In another embodiment, the structure of FIG.2B may be achieved by using a flat mold substrate 611 and a mask orstencil 730 overlaying a portion of substrate 611, as shown in FIG. 7B.

As shown in FIG. 2C, contact and die relief may also be controlled in astructure in which ACA 292 covers more than the exposed face of LEE 210.FIGS. 8A-8D show several exemplary approaches. In one embodiment, all ora portion of contacts 220 may be embedded in base 410 before molding ofphosphor 230, as shown in FIG. 8A. In one embodiment, all or a portionof contacts 220 and a portion of LEE 210 may be embedded in base 410before molding of phosphor 230, as shown in FIG. 8B. In one embodiment,base 410 may have recesses into which all or a portion of contacts 220are recessed, as shown in FIG. 8C. In one embodiment, base 410 may haverecesses into which all or a portion of contacts 220 and a portion ofLEE 210 may be recessed, as shown in FIG. 8D.

After singulation and optional expansion, ACA white dies 200 may beattached to a substrate featuring one or more conductive elements, suchthat the one or more contacts 220 are electrically coupled to one ormore conductive elements on the substrate through ACA 292. FIG. 9A showsstructure 900 featuring substrate 910 over which conductive elements 920are formed and an ACA white die 200 positioned over substrate 910 in aflip-chip mounting configuration where contacts are positioned overconductive traces 920 with a portion of ACA 292 between contacts 220 andconductive traces 920. Conductive traces 920 are configured with a gap930 between adjacent conductive traces 920 and ACA white die 200 ispositioned over gap 930 such that all or a portion of a first contact220 is over a portion of a first conductive element 920 and all or aportion of second contact 220 is positioned over a second conductiveelement 920. Contacts 220 are separated from conductive traces 920 byACA 292.

In some embodiments, ACA 292 is activated or cured, for example by usingheat, pressure, radiation (e.g., visible or UV light), magnetic field,or a combination of two or more of these activation methods, to create aconductive path between contacts 220 and conductive elements 920. In oneembodiment, ACA 292 is activated using a combination of heat andpressure. After positioning as shown in FIG. 9A, pressure and heat areapplied to activate ACA 292, resulting in the structure shown in FIG.9B. Positioning of dies 200 on substrate 910 may be performed by anytechnique; a common method of positioning is to utilize a pick-and-placetool that removes dies 200 from base 430 or 411 (FIGS. 4F and 4Grespectively) and places them over conductive elements 920. In someembodiments, the temperature for curing is in the range of about 70° C.to about 250° C., the pressure is in the range of about 4 gm to about800 gm force for a 20,000 μm² contact pad, and the curing time is in therange of about 10 seconds to about 30 minutes. In other embodiments, thebonding pressure (or force) is measured in Newtons, and an appropriatebonding force is in the range of about 0.01 to about 2.0 N for an areaof about 5000 μm². The force, temperature and time ranges used aredependent on the specific type of ACA 292 and are not a limitation ofthe present invention. In some embodiments, pressure is applied bycompressing the substrate and individual dies between two substantiallyrigid surfaces. In some embodiments, pressure is applied by compressingthe substrate and individual dies between a substantially rigid surfaceand a substantially compliant surface.

FIG. 9B shows a view of the bonding region, showing an example of abonded structure 901 after curing or activation of ACA 292. As shown inFIG. 9B, ACA 292 is compressed such that one or more conductiveparticles 226 form a conductive path between one contact 220 and oneconductive element 920. There is no electrical coupling between adjacentconductive elements 920 because the conductive particles 226 do not forman electrically continuous bridge between the two adjacent conductivetraces. While FIG. 9B shows one conductive particle 226 forming theconductive path between a contact 220 and a conductive element 920, thisis not a limitation of the present invention, and in other embodimentsmore than one conductive particle 226 may form the conductive pathbetween contact 220 and conductive element 920.

The structures described above may be combined with additionalelectronics to form an electronic device 903 as shown in FIG. 9C. In oneembodiment, the device includes multiple ACA white dies 200 that areelectrically coupled to traces 920. As shown, electronic device 903includes three serially-connected strings 980 of white dies 200.Electronic device 903 also includes circuitry 990 electrically connectedto one or more of strings 980. Circuitry 990 may include or consistessentially of portions or substantially all of the drive circuitry,sensors, control circuitry, dimming circuitry, and or power-supplycircuitry or the like, and may also be adhered (e.g., via an adhesive)or otherwise attached to substrate 910. In one embodiment, the powersupply and driver are distributed, e.g., the device 903 may have acentralized power supply and all or a portion of the drive circuitrydistributed in different locations. Circuitry 990 may even be disposedon a circuit board (e.g., a printed circuit board) that itself may bemechanically and/or electrically attached to substrate 910. In otherembodiments, circuitry 990 is separate from substrate 910. In someembodiments circuitry 990 is formed on substrate 910. While FIG. 9Cdepicts white dies 200 electrically coupled in serially connected instrings 980, and strings 980 connected or connectable in parallel, otherdie-interconnection schemes are possible and within the scope ofembodiments of the invention.

As shown in FIG. 9C, the lighting system 903 may feature multiplestrings, each string 980 including or consisting essentially of acombination of one or more white dies 200 electrically connected inseries, in parallel, or in a series-parallel combination with optionalfuses, antifuses, current-limiting resistors, zener diodes, transistors,and other electronic components to protect white die 200 from electricalfault conditions and limit or control the current flow throughindividual white dies 200. In general, such combinations feature anelectrical string that has at least two electrical connections for theapplication of DC or AC power. A string may also include a combinationof one or more white dies 200 electrically connected in series, inparallel, or in a series-parallel combination of white dies 200 withoutadditional electronic components. FIG. 9C shows three strings of whitedies 200, each string having three white dies 200 in series; however,this is not a limitation of the present invention, and in otherembodiments the number of strings is less than or greater than three andthe number of white dies 200 in a string is greater or less than three.In one embodiment, a string includes at least ten white dies 200. In oneembodiment, a string includes at least 45 white dies 200. In oneembodiment, system 903 includes at least ten strings. In one embodiment,system 903 includes at least 50 strings.

LEE substrate 910 may include or consist essentially of asemicrystalline or amorphous material, e.g., polyethylene naphthalate(PEN), polyethylene terephthalate (PET), acrylic, polycarbonate,polyethersulfone, polyester, polyimide, polyethylene, and/or paper. Inone embodiment, LEE substrate 910 includes or consists essentially ofPET and has a thickness in the range of about 10 μm to about 150 μm. LEEsubstrate 910 may also include or consist essentially of a rigid orflexible circuit board, for example FR4, metal core printed circuitboard (MCPCB), polyimide or the like. LEE substrate 910 may besubstantially flexible, substantially rigid or substantially yielding.In some embodiments, the substrate is “flexible” in the sense of beingpliant in response to a force and resilient, i.e., tending toelastically resume an original configuration upon removal of the force.A substrate may be “deformable” in the sense of conformally yielding toa force, but the deformation may or may not be permanent; that is, thesubstrate may not be resilient. Flexible materials used herein may ormay not be deformable (i.e., they may elastically respond by, forexample, bending without undergoing structural distortion), anddeformable substrates may or may not be flexible (i.e., they may undergopermanent structural distortion in response to a force). The term“yielding” is herein used to connote a material that is flexible ordeformable or both.

LEE substrate 910 may include multiple layers, e.g., a deformable layerover a rigid layer, for example, a semicrystalline or amorphousmaterial, e.g., PEN, PET, polycarbonate, polyethersulfone, polyester,polyimide, polyethylene, paint, plastic film and/or paper formed over arigid or substantially rigid substrate for example including, ceramicsuch as AlN, fiberglass, such as FR-4, metal core printed circuit board,acrylic, aluminum, steel and the like. In some embodiments, LEEsubstrate 910 is rigid or substantially rigid, for example includingsilicon, ceramic such as AlN, fiberglass, such as FR-4, metal coreprinted circuit board, acrylic, aluminum, steel and the like.

Depending upon the desired application for which embodiments of theinvention are utilized, LEE substrate 910 is substantially opticallytransparent, translucent, or opaque. For example, LEE substrate 910 mayexhibit a transmittance or a reflectivity greater than about 80% foroptical wavelengths ranging between approximately 400 nm andapproximately 700 nm. In some embodiments, LEE substrate 910 exhibits atransmittance or a reflectivity of greater than about 80% for one ormore wavelengths emitted by LEE 210 and/or white die 200. In someembodiments a reflective LEE substrate 910 advantageously aids indirecting light in a desired direction, while in some embodiments atransmissive LEE substrate 910 may provide a relatively transparentappearance or may permit light emission from both sides of LEE substrate910.

LEE substrate 910 may also be substantially insulating, and may have anelectrical resistivity greater than approximately 100 ohm-cm, greaterthan approximately 1×10⁶ ohm-cm, or even greater than approximately1×10¹⁰ ohm-cm.

Conductive traces 920 may include or consist essentially of anyconductive material, for example metals such as gold, silver, aluminum,copper, carbon and the like, conductive oxides, carbon, etc. Conductivetraces 920 may be formed on LEE substrate 910 by a variety oftechniques, for example evaporation, sputtering, physical deposition,chemical vapor deposition, plating, electroplating, printing,lamination, gluing using an adhesive, lamination and patterning or thelike. In one embodiment, conductive traces 920 are formed usingprinting, for example screen printing, stencil printing, flexo, gravure,ink jet, or the like. Conductive traces 920 may include or consistessentially of silver, aluminum, copper, gold, carbon inks, or otherconductive inks or the like. Conductive traces 920 may include orconsist essentially of a transparent conductor, for example, atransparent conductive oxide such as indium tin oxide (ITO). Conductivetraces 920 may include or consist essentially of a plurality ofmaterials. Conductive traces 920 may optionally feature stud bumps toaid in electrical coupling of conductive trace 920 to contacts 220.Conductive traces 920 may have a thickness in the range of about 0.05 μmto about 100 μm; however, this is not a limitation of the presentinvention, and in other embodiments conductive traces 920 may have anythickness. While the thickness of one or more of the conductive traces920 may vary, the thickness is generally substantially uniform along thelength of the conductive trace 920 to simplify processing. However, thisis not a limitation of the present invention and in other embodimentsthe conductive trace thickness or material varies. In one embodiment,LEE substrate 910 includes or consists essentially of PET having athickness in the range of about 10 μm to about 150 μm, and conductivetraces 920 include or consist essentially of either copper or aluminumand have a thickness in the range of about 5 μm to about 100 μm.

While FIG. 2A shows phosphor 230 having a square or rectangular shapearound LEE 210, this is not a limitation of the present invention. Insome embodiments, phosphor 230 is shaped by a mold 1030 that includes orconsists essentially of one or more compartments, depressions, or wells1020 into which LEEs 210 will be inserted or partially inserted or overor under which LEEs 210 will be suspended (for example, if barriersseparating the compartments do not extend sufficiently far to form fullyclosed compartments), as shown in FIG. 10A. In another embodiment, wells1020 are formed by insertion of a template into an open mold (such asthat shown in FIG. 4B). Wells 1020 are filled or partially filled withphosphor 420, for example by dispensing, by the doctor blade method,stencil printing, or by other means. Following formation of phosphor 420in wells 1020, temporary carrier or base 410 is mated with mold 1030such that LEEs 210 are fully or partially immersed in phosphor 420, asshown in FIG. 10B. Contacts 220 are adhered to temporary carrier 410,preventing phosphor 420 from covering at least a portion of contacts220. In one embodiment, phosphor 420 is introduced or injected intowells 1020 after mold 1030 is mated with base 410. In one aspect of thisembodiment, a partial vacuum may be used to enhance transport ofphosphor 420 to all wells 1020 and to partially or fully degas phosphor420 before curing. The process may include or consist essentially ofinjection molding, transfer molding, compression molding, casing, etc.Compression molding may be carried out using equipment such as a FFT-103manufactured by Towa Corporation. In some embodiments, mold 1030 isflat, i.e., effectively including only one depression 420 into whichfits multiple LEEs 210. In one embodiment, the structure of FIG. 10B isflipped, with base 410 on the bottom and mold 1030 on top, such thatphosphor 420 is formed over base 410 and LEE 210, over which a topportion 1031 of the mold 1030 is formed and in one embodiment of thisexample mold 1030 is a flat surface. For example, the structure of FIG.4B may be filled or over-filled with phosphor 420, after which a moldtop or cover 1031 is applied, as shown in FIG. 10D. The shape of mold1030 is not a limitation of the present invention and in otherembodiments mold 1030 has any shape. In some embodiments, both base 410and mold 1030 have raised barriers or sidewalls. As discussed herein, apattern, roughness or texture in all or a portion of the outer surfaceof phosphor 230 may be formed by introducing those features into thesurface of all or portions of the surface of the mold. In someembodiments, different LEEs 210 on base 410 have differently shapedphosphors formed around them.

In some embodiments all or a portion of mold 1030 is covered by a moldrelease material. In some embodiments, the mold release material is amold release film. In some embodiments, the mold release material ormold release film may be patterned, roughened or textured to, e.g.,impart similar features on all or portions of the outer surface ofphosphor 230. In some embodiments, the mold release material or moldrelease film may be smooth or substantially smooth.

FIGS. 11A-11D depict several embodiments of ACA white dies 200 that maybe fabricated with a shaped mold. The structure of FIG. 11A has asubstantially flat top and a reduced amount of phosphor over the cornersof LEE 210 than over the center of LEE 210. The structure of FIG. 11Bhas a non-smooth, for example textured, rough, or patterned, surface1110. In one embodiment, the non-smooth surface 1110 reduces totalinternal reflection (TIR) within phosphor 230 and achieves improvedlight extraction. In one embodiment surface 1110 may have a periodicstructure; however, this is not a limitation of the present invention,and in other embodiments the structure may be random. In one embodimentsurface 1110 include light extraction features (e.g., raised bumpsand/or depressions) having a dimension in the range of about 0.25 μm toabout 15 μm; however, this is not a limitation of the present invention,and in other embodiments the light extraction features may have otherdimensions. In one embodiment, the light extraction features may behemispherical or pyramidal in shape; however, this is not a limitationof the present invention, and in other embodiments the light extractionfeatures may have any shape. In one embodiment the light extractionfeature is a random texture or roughness with an average roughness inthe range of about 0.25 μm to about 15 μm. In the structure of FIG. 11C,the phosphor is shaped in a rounded shape. Such a rounded shape may be ahemisphere, a paraboloid, a Fresnel optic or any other shape.

The structure of FIG. 11D has a photonic crystal 1120 formed on the topsurface. In one embodiment, the photonic crystal 1120 increases theintensity of light exiting white die 200 in a specific direction, forexample perpendicular to the face of white die 200. In otherembodiments, a photonic crystal is formed on all or a portion of anysurface of white die 200. FIG. 11E shows a portion of a white waferhaving contiguous molded shapes over LEEs 210. In some embodiments, thestructure shown in FIG. 11E may produce more white dies 200 per unitarea than the structure shown in FIG. 11F, and this may be advantageousfrom a manufacturing cost point of view. In some embodiments, this issingulated, for example at the joining line 1130 to form individualwhite dies 210, while in other embodiments a white die 210 may include aplurality of LEEs 210 with a plurality of shaped phosphors 230, as shownin FIG. 11F. As shown in FIG. 11F, the shaped phosphors 230 may beconnected by a thin region 1150. In some embodiments region 1150 may beadvantageously minimized to reduce the consumption of unused phosphor,for example by minimizing the thickness and/or lateral extent of region1150. However, this is not a limitation of the present invention, and inother embodiments region 1150 may have any shape or size or may beabsent, as described herein.

In one embodiment, the phosphor may be shaped by forming a white die asshown in FIG. 2A or a white die wafer as shown in FIG. 4C and thenremoving one or more portions of the phosphor to produce a shapedifferent from the starting shape. Removal of one or more portions ofthe phosphor may be accomplished using a variety of means, for exampleknife cutting, dicing, laser cutting, die cutting, ablation or the like.

While the examples herein generally show LEEs 210 spaced in a regularperiodic array on base 410, this is not a limitation of the presentinvention, and in other embodiments LEEs 210 are arrayed or spaced inany fashion on base 410. While the examples herein show rectangular LEEs210, this is not a limitation of the present invention, and in otherembodiments the LEE 210 are square, triangular, hexagonal, round or anyother shape. The examples discussed above for white die 200 show one LEE210 in each white die 200. However, this is not a limitation of thepresent invention and in other embodiments each white die 200 includes aplurality of LEE 210, as shown in FIGS. 12A-12C. FIG. 12A shows across-sectional view of a multi-LEE white die incorporating five LEEs210. FIG. 12B shows a plan view of a multi-LEE white die incorporatingnine LEEs 210 in a 3×3 array. FIG. 12C shows a plan view of a multi-LEEwhite die incorporating four LEEs 210 in a 1×4 array. The examples inFIG. 12A-12C show rectangular white dies; however, this is not alimitation of the present invention, and in other embodiments the whitedie are square, triangular, hexagonal, round or any other shape. InFIGS. 12B and 12C, ACA 292 is not shown to illustrate the position ofLEE 210 within the structure. The examples in FIG. 12A-12C show LEEs 210in a regular periodic array; however, this is not a limitation of thepresent invention, and in other embodiments LEEs 210 are arrayed orspaced in any fashion.

Examples discussed above for white dies 200 show white dies 200 as beingsquare and having sidewalls perpendicular to the contact face of LEE210. However, this is not a limitation of the present invention and inother embodiments white die 200 is rectangular, hexagonal, circular,triangular, or has any arbitrary shape, and/or has sidewalls forming anyangle with respect to the surface of LEE 210 including contacts 220.While the term white die, for example related to white die 200, has beenused to describe a structure producing white light, this is not alimitation of the present invention, and in other embodiments, differentcolor LEEs 210 and different phosphors (one or more) may be used toproduce other colors, for example amber, green or any arbitrary color orspectral power distribution. In other embodiments, a white die 200includes multiple LEEs 210. In some embodiments, the LEEs 210 are allthe same, while in other embodiments the LEEs 210 include two or moregroups of different LEEs 210, for example emitting at differentwavelengths. In some embodiments, an LEE 210 may include or consistessentially of an organic light emitter.

While examples discussed above utilize ACA without stud bumps, this isnot a limitation of the present invention and in other embodiments studbumps may be utilized to aid in making electrical contact between theACA and the electrical traces on a substrate. FIG. 13A shows structure1300 that is similar to white die 200 of structure 900 (separate fromsubstrate 910 and conductive traces 920) of FIG. 9A, but with theaddition of stud bumps 1310. FIG. 13B shows structure 1301, similar tostructure 901 of FIG. 9B, after curing of ACA 292, showing ACA particle226 between stud bump 1310 and conductive trace 920.

In one embodiment, die 210 includes or consists essentially of an LEEdie, for example an LED or laser. FIGS. 14A and 14B depict an exemplaryLEE 1700 for use in an embodiment of the present invention. FIG. 14Ashows a cross-sectional view, while FIG. 14B shows a top plan view ofLEE 1400. LEE 1400 typically includes a substrate 1410 with one or moresemiconductor layers disposed thereover. In this exemplary embodiments,LEE 1400 represents a light-emitting device such as a LED or a laser,but other embodiments of the invention feature one or more semiconductordies with different or additional functionality, e.g., processors,sensors, photovoltaic solar cells, detectors, and the like. DifferentLED dies or non-LED dies may have contact geometries differing fromthose of LEDs. While FIGS. 14A and 14B show LEE 1400 having non-coplanarcontacts 1460 and 1470, this is not a limitation of the presentinvention and in other embodiments LEE 1400 may have coplanar orsubstantially coplanar contacts, as shown in FIG. 2A.

Substrate 1410 may include or consist essentially of one or moresemiconductor materials, e.g., silicon, GaAs, InP, GaN, and may be dopedor substantially undoped (e.g., not intentionally doped). In someembodiments, substrate 1410 includes or consists essentially of sapphireor silicon carbide. Substrate 1410 may be substantially transparent to awavelength of light emitted by the LEE 1400. As shown for alight-emitting device, LEE 1400 may include first and second dopedlayers 1420, 1440, which preferably are doped with opposite polarities(i.e., one n-type doped and the other p-type doped). One or morelight-emitting layers 1430, e.g., one or more quantum wells, may bedisposed between layers 1420, 1440. Each of layers 1420, 1430, 1440 mayinclude or consist essentially of one or more semiconductor materials,e.g., silicon, InAs, AlAs, GaAs, InP, AlP, GaP, InSb, GaSb, AlSb, GaN,AlN, InN, and/or mixtures and alloys (e.g., ternary or quaternary, etc.alloys) thereof. In preferred embodiments, LEE 1400 is an inorganic,rather than a polymeric or organic, device.

As shown in FIGS. 14A and 14B, in some embodiments LEE 1400 is patternedand etched (e.g., via conventional photolithography and etch processes)such that a portion of layer 1420 is exposed in order to facilitateelectrical contact to layer 1420 and layer 1440 on the same side of LEE1400 (and without, for example, the need to make contact to layer 1420through substrate 1410 or to make contact to layer 1420 with a shuntelectrically connecting a contact pad over layer 1440 to layer 1420).One or more portions of layers 1430, 1440 are removed (or never formed)in order to expose a portion of layer 1420, and thus FIG. 14A depicts asurface 1425 of LEE 1400 that is non-planar, i.e., contains exposedportions non-coplanar with each other. Surface 1425 corresponds to theouter surface of LEE 1400, including any contour or topography resultingfrom portions of layers not being present. In order to facilitateelectrical contact to LEE 1400, discrete electrical contacts 1460, 1470are formed on layers 1440, 1420, respectively. Electrical contacts 1460,1470 may each include or consist essentially of a suitable conductivematerial, e.g., one or more metals or metal alloys, conductive oxides,or other suitable conductive materials and are generally non-coplanar(particularly in embodiments when having approximately equalthicknesses), as depicted in FIG. 14A. In some embodiments, surface 1425is planar or substantially planar. In some embodiments, the top surfacesof electrical contacts 1460 and 1470 are coplanar or substantiallycoplanar. The structure shown in FIGS. 14A and 14B is for illustrativepurposes. There are a wide variety of designs for LEE 210 or LEE 1400,and the specific design of LEE 210 or LEE 1400 is not a limitation ofthe present invention. For example, in some embodiments LEE 210 or LEE1400 may have different shaped contacts, different area contacts,different approaches to contact the semiconductor material or the like.

In some embodiments, LEE 1400 has a square shape, while in otherembodiments LEE 1400 has a rectangular shape. The shape and aspect ratioare not critical to the present invention, however, and LEE 1400 mayhave any desired shape. In various embodiments, the extent of one orboth of contacts 1460, 1470 in one dimension (e.g., a diameter or sidelength) is less than approximately 100 μm, less than approximately 70μm, less than approximately 35 μm, or even less than approximately 20μm. In one embodiment, contacts 1460, 1470 are rectangular and may havea length in the range of about 10 μm to about 250 μm and a width in therange of about 5 μm to about 250 μm. In some embodiments, contacts 1460,1470 have one dimension that is at least 200 μm or that is at least 500μm. In other embodiments, contacts 1460, 1470 have any shape or size,and in some embodiments LEE 1700 has more than two contacts. The number,shape and aspect ratio of the contacts are not critical to the presentinvention, however, and contacts 1460, 1470 may have any desired number,shape and/or size. In some embodiments, the separation between contacts1460 and 1470 is at least 50 μm, or at least 100 μm, or at least 200 μm.In some embodiments, contacts 1460 and 1470 are separated as far aspossible within the geometry of LEE 1400. For example, in one embodimentthe separation between contacts 1460 and 1470 is in the range of about75% to over 90% of the length of LEE 1400; however, the separationbetween contacts is not a limitation of the present invention.

Particularly if LEE 1400 includes or consists essentially of alight-emitting device such as a LED or laser, contacts 1460, 1470 may bereflective to a wavelength of light emitted by LEE 1400) and hencereflect emitted light back toward substrate 1410. In some embodiments, areflective contact 1460 covers a portion or substantially all of layer1440, while a reflective contact 1470 covers a portion or substantiallyall of exposed layer 1420. In addition to or instead of reflectivecontacts, a reflector (not shown in this figure for clarity) may bedisposed between or above portions of contacts 1460, 1470 and overportions or substantially all of layer 1440 and 1420. The reflector isreflective to at least some or all wavelengths of light emitted by LEE1400 and may include or consist essentially of various materials. In oneembodiment, the reflector is non-conductive so as not to electricallyconnect contacts 1460, 14870. In some embodiments, the reflector may bea Bragg reflector. In some embodiments, the reflector may include orconsist essentially of one or more conductive materials, e.g., metalssuch as silver, gold, platinum, etc. Instead of or in addition to thereflector, exposed surfaces of semiconductor die except for contacts1460, 1470 may be coated with one or more layers of an insulatingmaterial, e.g., a nitride such as silicon nitride or an oxide such assilicon dioxide. In some embodiments, contacts 1460, 1470 include orconsist essentially of a bond portion for connection to a circuit boardor power supply or the like and a current-spreading portion forproviding more uniform current through LEE 1400, and in someembodiments, one or more layers of an insulating material are formedover all or portions of LEE 1400 except for the bond portions ofcontacts 1460, 1470. Insulating material 1450 may include or consistessentially of, for example, polyimide, silicon nitride, silicon oxideand/or silicon dioxide. Such insulating material 1450 may cover all orportions of the top and sides of LEE 1400 as well as all or portions ofthe top and sides of layers 1420, 1430 and 1440. Insulating material1450 may act to prevent shorting between contacts 1460 and 1470 andbetween conductors to which contacts 1460 and 1470 may be electricallycoupled.

FIG. 15 shows one embodiment of white die 200 incorporating an LEE 1400as described above. White die 200 as shown in FIG. 15 may bemanufactured in accordance with any of various embodiments of thepresent invention. FIG. 15 shows ACA 292 overlaying and/or laminated tosemiconductor die 1400. As described above, ACA 292 is generally formedover multiple semiconductor dies 1400 prior to singulation. In someembodiments, ACA 292 is completely or substantially conformal to thesurface of semiconductor dies 1400 and/or phosphor 230. However, this isnot a limitation of the present invention, and in other embodiments ACA292 is not conformal or substantially conformal to the surface ofsemiconductor dies 1400 and/or phosphor 230.

In some embodiments, phosphor 230 absorbs a portion of the incidentshort-wavelength radiant flux from LEE 210 and re-emits long-wavelengthradiant flux. In an exemplary YAG:Ce phosphor a blue LED typically has apeak wavelength of 440 nm-470 nm, corresponding to the peak of thephosphor-excitation spectrum, while the phosphor emission has abroadband spectrum with a peak at approximately 560 nm. Combining theblue LED emission with the yellow phosphor emission yields visible whitelight with a specific chromaticity (color) that depends on the ratio ofblue to yellow light. Herein, “white light” may be white or any othercolor that is produced by a combination of light from one or more lightemitters and one or more light-conversion materials. Herein, phosphormay refer to one or more phosphors producing a desired spectral powerdensity. Advantageously, embodiments of the present invention producewhite dies 200 having controlled phosphor thickness, uniformity, anddistribution of phosphor particles in the binder around LEE 210, forexample, a uniform or substantially uniform thickness and uniform orsubstantially uniform distribution of phosphor particles in the binder,or an engineered thickness and distribution of phosphor particles toachieve uniform or otherwise specified optical characteristics. Thethickness and distribution, or loading, of the phosphor particles mayhave a strong impact on the uniformity of the color temperature of thelight. In systems with multiple LEEs, and in particular arrays with tensto thousands of LEEs, it may be difficult to achieve such phosphorcoating over all of the LEEs when utilizing conventionalphosphor-integration techniques, resulting in non-uniform opticalcharacteristics. The aforementioned method for fabrication of uniformthickness and composition phosphor as part of white die 200 results in areduction in the variation in color temperature and thus a more uniformcolor temperature light source, both within a lighting system featuringan array of phosphor-converted LEEs, as well as between such lightingsystems. The use of the aforementioned LEEs in lighting systemsfeaturing large arrays of LEEs permits the manufacture of large numbersof lighting systems having uniform color temperatures. In someembodiments, white dies 200 are manufactured that have a distribution ofcolor temperature less than about 500K, or less than about 250K, or lessthan about 125K, or less than about 75K. In some embodiments, white dies200 are manufactured that have a variation in color temperature orchromaticity of less than about four MacAdam ellipses, or less thanabout two MacAdam ellipses, or less than about one MacAdam ellipse. Insome embodiments, such tight distributions are achieved within one whitewafer, or within a batch of white wafers or within the entiremanufacturing distribution.

In some embodiments, substantially all or a portion of substrate 1410 isremoved prior to formation of the phosphor, as described below. Suchremoval may be performed by, e.g., chemical etching, laser lift-off,exfoliation, mechanical grinding and/or chemical-mechanical polishing,or the like. In some embodiments, all or a portion of substrate 1410 maybe removed and a second substrate—e.g., one that is transparent to orreflective of a wavelength of light emitted by LEE 1400—is attached tosubstrate 1410 or semiconductor layer 1420 prior to formation of thephosphor as described herein. In some embodiments, substrate 1410includes or consists essentially of silicon, and all or a portion ofsilicon substrate 1410 may be removed prior to phosphor formation asdescribed below. Such removal may be performed by, e.g., chemicaletching, laser lift off, mechanical grinding and/or chemical-mechanicalpolishing, or the like. In some embodiments, substrate 1410 is used as atemplate for growth of the active layers of the device, for examplelayers 1420, 1430, and 1440. In some embodiments, in use, substrate 1410provides mechanical support but does not provide an electrical oroptical function and may be removed. In some embodiments, removal ofsubstrate 1410 during the formation process for the white die includesremoval of all or a portion of substrate 1410 that does not provideelectrical functionality (e.g., does not contribute to the emission ordetection of light).

FIG. 16 shows structure 1600 which is similar to the structure shown inFIG. 15, but with substrate 1410 removed. In one embodiment, structure1600 may be formed using a process similar to that described in relationto FIGS. 4A-4G, where substrate 1410 is removed between the stepsassociated with FIG. 4A and FIG. 4B. For example after LEEs 210 areformed on base 410, substrate 1410 is removed or partially removed, forexample, using a laser lift-off process. After completion of theprocess, the resulting ACA white die is similar to that shown in FIG.16. In another embodiment, base 410 is used to hold LEE 210 while aportion or all of substrate 1410 is mechanically and/or chemicallyremoved. In another embodiment, a process similar to that described inrelation to FIGS. 6A-6G may be used, where substrate 1410 is removedbetween the steps associated with FIG. 6B and FIG. 6D. In oneembodiment, the structure shown in FIG. 6B is mounted on base 610, andsubstrate 1410 is removed before or after singulation. In oneembodiment, substrate 1410 is removed after singulation and expansion atthe point in the process shown in FIG. 6D. As discussed herein,singulation may be accomplished by a variety of means, for exampleincluding laser lift-off, mechanical polishing and/or lapping,exfoliation and chemical etching.

In one embodiment, structures like those shown in FIGS. 17A-17C may beformed by adding an array of optical elements to the mold during thefabrication process. FIG. 18 shows an optical array 1810 of opticalelements between mold top 1820 and phosphor 230. In some embodiments,optical element 1710 may be a Fresnel optic or a refractive optic. Insome embodiments, optical element 1710 may initially be part of an arrayof optical elements such as optical array 1810 as discussed herein,while in other embodiments, one or more optical elements 1710 may bepositioned individually in the formation process. In one embodiment,optical array 1810 may be all or a portion of the mold top 1820.

In another embodiment, optical array 1810 may be joined to an ACA whitedie wafer after fabrication of ACA white die wafer, for example betweenthe steps associated with FIG. 4E and FIG. 4F or between the stepsassociated with FIGS. 6E and 6F. In one embodiment, phosphor 430 may bepartially cured, mated to optical array 1810, and then be subjected toadditional curing to physically attach optical array 1810 to thephosphor. In one embodiment, an adhesive may be used to attach opticalarray 1810 to the white die wafer. Examples of adhesives include opticaladhesives, spray adhesives, adhesive tape, polyurethane, the samematerial used as the binder for phosphor 230, or the like. The method ofattachment of optical array 1810 to the white die wafer is not alimitation of the present invention. In some embodiments, the adhesivehas an index of refraction that provides index matching between phosphor230 and optical array 1810. In some embodiments, after attachment ofoptical array 1810 to the white die wafer, singulation takes place toseparate the structure into smaller elements, each containing at leastone LEE 210 and one optical element 1710.

As shown, optical array 1810 includes or consists essentially of one ormore optical elements 1710, which in FIGS. 17A-17C and FIG. 18 arealigned or substantially aligned with white dies 200. Optical array 1810typically features an array of optical elements 1710; in someembodiments, one optical element 1710 is associated with each white die200, while in other embodiments multiple white dies 200 are associatedwith one optical element 1710, or multiple optical elements 1710 areassociated with a single white die 200, or no engineered optical elementis associated with any white die 200, for example all or portions ofoptical array 1810 may be a plate with a flat or roughened surface. Inone embodiment, optical array 1810 includes elements or features toscatter, diffuse and/or spread out light generated by white dies 200.

Optical array 1810 may be substantially optically transparent ortranslucent. For example, optical array 1810 may exhibit a transmittancegreater than 80% for optical wavelengths ranging between approximately400 nm and approximately 600 nm. In one embodiment, optical array 1810includes or consists essentially of a material that is transparent to awavelength of light emitted by white dies 200. Optical array 1810 may besubstantially flexible or rigid. In some embodiments, optical array 1810includes multiple materials and/or layers. Optical elements 1710 may beformed in or on optical array 1810. Optical array 1810 may include orconsist essentially of, for example, acrylic, polycarbonate,polyethylene naphthalate (PEN), polyethylene terephthalate (PET),polycarbonate, polyethersulfone, polyester, polyimide, polyurethane,silicone, glass, or the like. Optical elements 1710 may be formed byetching, polishing, grinding, machining, molding, embossing, extruding,casting, or the like. The method of formation of optical elements 1710is not a limitation of embodiments of the present invention.

Optical elements 1710 associated with optical array 1810 may all be thesame or may be different from each other. Optical elements 1710 mayinclude or consist essentially of, e.g., a refractive optic, adiffractive optic, a total internal reflection (TIR) optic, a Fresneloptic, or the like, or combinations of different types of opticalelements. Optical elements 1710 may be shaped or engineered to achieve aspecific light distribution pattern from the array of light emitters,phosphors and optical elements.

As used herein, “alignment” and “aligned” may mean that the center ofone structure, for example a white die 200, is aligned with the centerof another structure, for example an optical element 1710.

In one embodiment of the present invention, a reflecting layer is formedbetween all or a portion of the region between phosphor 230 and ACA 292,for example to reflect light back in a direction away from the ACA. Insome embodiments, ACA may partially absorb a portion of the lightemitted by the white die, and it may be advantageous to reflect thelight rather than allowing it to be absorbed by the ACA. FIG. 19A showsa white die 1900 that is similar to that shown in FIG. 2A, with theinclusion of a reflecting layer 1910. Reflecting layer 1910 may bereflective to a wavelength of light emitted by phosphor 230 and/or LEE210. In some embodiments, reflecting layer 1910 has a reflectivitygreater than 40% to a wavelength of light emitted by phosphor 230 and/orLEE 210. In some embodiments, reflecting layer 1910 has a reflectivitygreater than 60% to a wavelength of light emitted by phosphor 230 and/orLEE 210. In some embodiments, reflecting layer 1910 has a reflectivitygreater than 80% to a wavelength of light emitted by phosphor 230 and/orLEE 210. FIG. 19B shows a simulation of a white die in which thereflectance of reflecting layer 1910 is varied from 0 to 100%. As may beseen, in some embodiments increasing the reflectance results in asubstantial increase in light output power (LOP). For this example, ifreflecting layer 1910 has almost no reflectivity, the light output poweris about 0.9 lm, while if reflecting layer 1910 has about 100%reflectivity, the light output power is about 1.8 lm, which is anincrease by a factor of about two.

There are a number of ways in which a reflecting layer may be formed. Inone embodiment, a powder, particulate or beads of a material that isreflective to a wavelength of light emitted by phosphor 230 and/or LEE210 is dispersed over mold substrate 410 after positioning of LEEs 210on mold substrate 410, as shown in FIG. 20A. As shown in FIG. 20A, thismay result in a portion 2020 of the powder on top of LEEs 210 and aportion 2010 of the powder directly on mold substrate 410. In someembodiments, powder 2010 may adhere to mold substrate 410 but theportion 2020 may not adhere well to the top of LEE 210, and thestructure shown in FIG. 20A may be tilted, inverted, exposed to a jet ofgas, shaken, or otherwise processed to remove powder 2020 on top of LEEs210. The white die formation process may then be applied to thestructure shown in FIG. 20B, resulting in white die 2000 wherereflecting layer 1910 is composed of the reflecting powder. In someembodiments, the reflective powder may include at least one ofpolystyrene, polyester, glass, barium titanate glass, gold, silver,aluminum, mica, silica, PMMA, fumed silica, fumed alumina, TiO₂ or thelike; however, the composition of the reflective powder is not alimitation of the present invention.

In some embodiments, powder 2010, 2020 is formed of particles that havea dimension in the range of about 0.01 μm to about 100 μm, or preferablyin the range of about 1 μm to about 50 μm. In some embodiments, thelayer of phosphor into which is adhered, embedded or infused powder2010, 2020 has a thickness in the range of about 0.1 μm to about 50 μm.In some embodiments, it is advantageous for the thickness of the layerof phosphor into which powder 2010, 2020 is adhered, embedded or infusedto be less than the thickness of LEE 210, such that it does not occludethe light emitted from the side of LEE 210. In some embodiments, thephosphor layer into which powder 2010, 2020 is adhered, embedded orinfused has a thickness less than about 50% of the thickness of LEE 210,or less than about 25% of the thickness of LEE 210, or less than about10% of the thickness of LEE 210.

In some embodiments, material 2010, 2020 includes or consistsessentially of reflective or partially reflective beads, for examplehaving a spherical or substantially spherical shape. In someembodiments, the particles or beads may be solid, while in otherembodiments the particles or beads may be hollow. In some embodiments,beads 2010, 2020 may have a diameter in the range of about 0.1 μm toabout 150 μm, while in other embodiments they may have a diameter in therange of about 1 μm to about 75 μm. In some embodiments, the beads maybe white and have a reflectivity to a wavelength of light emitted by LEE210 and/or phosphor 230 greater than about 70%. In some embodiments, thebeads or particles may have a refractive index of at least 1.35, or atleast 1.5, or at least 1.9. In some embodiments, the beads or particleshave a refractive index that is at least 10% larger than the refractiveindex of the phosphor or binder or at least 25% larger than therefractive index of the phosphor or binder. In some embodiments, theparticles may include or consist essentially of more than one material.For example, in some embodiments, the particles may include or consistessentially of a core, which may be solid or hollow, and one or morecoatings. For example in some embodiments, the particle may include orconsist of a glass or polymer bead or sphere that is coated withaluminum, gold, silver or the like. In some embodiments, the particle orsphere may be coated with multiple coatings, for example to form a Braggmirror. In one embodiment, the beads may act as retro-reflectors thatsubstantially redirect the light back in the direction from which it wasincident on the bead.

In some embodiments, a portion of the beads or particles may protrudefrom phosphor 230, as shown in FIGS. 21A and 21B. In some embodiments,particles 2110 or 2120 may protrude or extend from phosphor 230. In someembodiments, at least 5% of the particle may protrude from phosphor 230.In some embodiments, at least 20% of the particle may protrude fromphosphor 230. In some embodiments, at least 40% of the particle mayprotrude from phosphor 230. In some embodiments, the protruding portionof the particle may be covered or partially covered by a relatively thinlayer of phosphor or binder material. In some embodiments, theprotruding portion of the particle may be in contact with ACA 292.

In one embodiment, the reflecting layer is formed using a reflectivefilm. For example, a reflecting film 1910, similar to a mold releasefilm, may be positioned over a portion of mold substrate 410, as shownin FIG. 22A. After formation and curing of phosphor 230 and singulation,reflecting film 4510 adheres to and/or is embedded into cured phosphor230 of the white die instead of acting to reduce adhesion between curedphosphor 230 and mold substrate 410, as is the case with the moldrelease film, as shown in FIG. 22B. As discussed herein, the film may,by itself or in combination with other approaches, be used to controldie and contact relief. In some embodiments, reflective film 1910includes or consists essentially of metal films or foils such as Cr, Al,Au, Ag, Cu, Ti, or the like. In some embodiments, reflective layer 1910may include or consist essentially of more than one layer. In someembodiments, reflective layer 1910 may include or consist essentially ofmultiple layers of metal. In one embodiment, reflective film 1910 mayhave a thickness in the range of about 0.25 μm to about 50 μm, orpreferably in the range of about 5 μm to about 35 μm. In someembodiments, the thickness of reflective film 1910 is chosen such thatit is not thick enough to occlude a substantial portion of light emittedfrom the side(s) of LEE 210. In one embodiment, reflective film 1910 isa foil that has been patterned with holes corresponding to the positionof LEEs 210 on mold substrate 410. In some embodiments, the thickness ofthe reflective film or particles is advantageously less than thethickness of LEE 210, for example less than about 50% of the thicknessof LEE 210, or less than about 25% of the thickness of LEE 210, or lessthan about 10% of the thickness of LEE 210.

In one embodiment, reflective layer 1910 may be deposited on moldsubstrate 410 and patterned to permit positioning of LEEs 210 directlyon mold substrate 410. In one embodiment, reflective layer 1910 may beapplied selectively to mold substrate 410, for example through a shadowmask or selectively applied by evaporation, sputtering, spraying, or thelike. In one embodiment, a reflecting layer may be formed by printing,for example screen, stencil, ink jet, gravure, flexo printing or thelike. In one embodiment, reflective layer 1910 may be composed of morethan one layer of materials, for example a carrier and a reflectivelayer. For example, in some embodiments, reflecting layer 1910 mayinclude or consist essentially of a support substrate that includes orconsists essentially of a semicrystalline or amorphous material, e.g.,polyethylene naphthalate (PEN), polyethylene terephthalate (PET),acrylic, polycarbonate, polyethersulfone, polyester, polyimide,polyethylene, and/or paper and the reflecting film may include orconsist essentially of aluminum, gold, silver, copper, ink or the like.

In another embodiment, reflective layer 1910 may be applied to the whitewafer after it is formed. For example, in some embodiments, reflectivelayer 1910 may be formed by deposition of a reflecting layer on thebottom of the white wafer, where, in some embodiments, the reflectivematerial is formed such that it does not come in electrical contact withany portion of the electrical contacts of LEEs 210. In some embodiments,this may be done by deposition of a metal layer, for example, Cr, Al,Au, Ag, Cu, Ti or the like, for example by evaporation, physical vapordeposition, sputtering, chemical vapor deposition, plating or the like.In some embodiments, it may be accomplished by lamination of a patternedfoil. FIG. 23A shows an example of one embodiment of a white waferincluding or consisting essentially of LEEs 210 and phosphor 230. Inthis example, phosphor 230 has a dome-like shape; however, this is not alimitation of the present invention, and in other embodiments phosphor230 may have any shape. FIG. 23B shows the structure of FIG. 23A at alater stage of manufacture, where reflecting layer 1910 has been formedover a portion of phosphor 230. In the example shown in FIG. 23B,reflecting layer 1910 is formed over substantially all of the face ofphosphor 230 containing contacts 220 of LEEs 210. FIG. 23C shows a planview of the structure of FIG. 23B, from the side facing reflecting layer1910. In this example, reflecting layer 1910 covers substantially all ofthe phosphor on this face, except for a region around each LEE 210. InFIG. 23C, reflecting layer 1910 is identified as the cross-hatchedregion and the edge of the dome of phosphor 230 is identified as 2310.In subsequent steps, ACA 292 is applied over reflecting layer 1910 andthe resulting structure is singulated; FIG. 23D shows an example of thestructure after formation of ACA 292 and singulation. In this example,reflecting layer 1910, ACA 292, and a portion of phosphor 230 areseparated to form the individual ACA white dies.

A gap 2320 between LEE 210 and reflecting layer 1910 is shown in FIG.23C as being the same or substantially the same around the entireperiphery of LEE 210; however, this is not a limitation of the presentinvention, and in other embodiments the gap may vary. In someembodiments, the gap may have a value in the range of about 0 μm toabout 300 μm, while in other embodiments the gap may have a value in therange of about 25 μm to about 100 μm; however, in some embodiments, thegap is preferably kept as small as possible to increase the amount oflight reflected by reflecting layer 1910. In some embodiments, the gapmay be negative, that is reflecting layer 1910 may cover a portion ofLEE 210. As will be discussed herein, in some embodiments reflectinglayer 1910 may cover all or a portion of contacts 220.

In some embodiments, it may be advantageous to form separate regions ofreflecting layer 1910 before singulation of the white die wafer. Forexample, the singulation technique and process parameters may berelatively difficult to optimize for multiple sets of materials, forexample in the case where reflecting layer 1910 includes or consistsessentially of a metal and phosphor 230 includes or consists essentiallyof a polymer. FIG. 24A shows an example of a structure similar to thatof FIG. 23B, with the exception that reflecting layer 1910 is absentfrom a region 2410 between ACA white dies, as shown in FIG. 24A, alsoknown as the street region, where singulation of the white die waferoccurs. FIG. 24B shows an expanded view of the region between twoadjacent white dies. In the example shown in FIG. 24B, reflecting layer1910 extends into street region 2410 by an amount 2420. In someembodiments, the extension amount 2420 may be positive, as shown in FIG.24B, where reflecting layer 1910 extends into street region 2410, whilein other embodiments, extension amount 2420 may be negative, that isthere is a gap between reflecting layer 1910 and street region 2410. Insome embodiments, a positive extension 2420 may have a value in therange of about 0 to about 25% of the width of street region 2410;however, this is not a limitation of the present invention, and in otherembodiments extension 2420 may have any value. In some embodiments anegative extension 2420 may have a value in the range of about 0 toabout 25% of the width of the white die; however, this is not alimitation of the present invention, and in other embodiments extension2420 may have any value. However, a negative extension 2420 willdecrease the reflecting area, and in some embodiments, a negativeextension 2420 is minimized or eliminated. In some embodiments, streetregion 2410 is advantageously minimized to increase the number ofdevices manufactured per unit area and to minimize cost. While thediscussion in reference to FIGS. 23A-23D and 24A and 24B has been withrespect to dome-shaped phosphor 230, this is not a limitation of thepresent invention, and in other embodiments phosphor 230 may have anyshape.

While FIG. 24B shows reflecting layer 1910 having a thickness 2430 lessthan contact relief 298 this is not a limitation of the presentinvention and in other embodiments reflecting layer 1910 may have athickness 2340 greater than contact relief 298 or may have a thicknessequal to contact relief 298. However, in some embodiments, contactrelief 298 is advantageously larger than thickness 2340, in order to aidin making low-contact resistance, robust connection to contacts 220.

In some embodiments, all or a portion of contacts 220 may be covered byreflecting layer 1910. In such embodiments, it is preferable thatreflecting layer 1910 is conductive, such that current may flow fromcontacts 220 through reflecting layer 1910 and ACA 292 to, for example,an underlying conductive trace or substrate. Examples of conductivereflecting materials may include, for example, Cr, Al, Au, Ag, Cu, Ti orthe like, conductive inks such as silver ink, carbon ink, copper ink, orthe like. FIG. 25A shows an example of an ACA white die in whichcontacts 220 are covered by reflecting layer 1910. While the structureof FIG. 25A shows contacts 220 being completely covered by reflectinglayer 1910, this is not a limitation of the present invention, and inother embodiments only a portion of contacts 220 may be covered byreflecting layer 1910. FIG. 25B shows one embodiment of the structure ofFIG. 25A at an early stage of manufacture. FIG. 25B shows a white waferincluding or consisting essentially of LEEs 210 and phosphor 230. FIG.25C shows the structure of FIG. 25B at a later stage of manufacture,where reflecting layer 1910 has been formed over portions of phosphor230 and LEEs 210 such that contacts 220 of LEE 210 are covered byreflecting layer 1910. In some embodiments, reflecting layer 1910 may beformed over the entire surface of the white wafer containing contacts220 and subsequently removing portions of reflecting layer 1910 toproduce the structure of FIG. 25C. For example reflecting layer 1910 maybe formed by physical vapor deposition, chemical vapor deposition,evaporation, sputtering, plating, lamination, spraying, printing, screenprinting, or the like. This layer may then be patterned, for example bylithography, and portions removed, for example by etching, wet chemicaletching, dry etching, RIE, ablation, or the like. In another embodiment,reflecting layer may be deposited selectively. For example, reflectinglayer 1910 may be deposited through a physical or shadow mask usingevaporation, sputtering or the like, or may be deposited using aselective deposition process that results in reflecting layer 1910 onlyforming in specific regions, or may be accomplished by lamination orformation of a patterned film or foil of reflecting layer 1910 onphosphor 230.

In the example shown in FIG. 25C, reflecting layer 1910 is not formed inthe street or singulation region, identified as 2510; however, this isnot a limitation of the present invention, and in other embodimentsreflecting layer 1910 may be formed in street or singulation region2510. In some embodiments, it may be advantageous to not form reflectinglayer 1910 in the street or singulation region, as this may simplify thesingulation process. As may be seen in FIG. 25C, the portions ofreflecting layer 1910 that are coupled to each contact 220 are notelectrically coupled to each other, to avoid shorting LEE 210. FIG. 25Dshows the structure of FIG. 25C at a later stage of manufacture, afterformation of ACA 292 and singulation, resulting in the structure of FIG.25A.

In some embodiments, a patterned conductive film or foil of reflectingmaterial 1910 may be formed on mold substrate 410 or another base, in afashion similar to that shown in FIG. 22A, but where the conductive foilis under all or a portion of contacts 220, as shown in FIG. 25E suchthat current flows to LEE 210 through conductive foil 1910 and contacts220. Portions of the conductive foil may be electrically coupled tocontacts 220, for example using solder, low temperature solder,conductive epoxy, ACA, ACF, physical mating or the like. FIG. 25F showsan example of the structure of FIG. 25E at a later stage of manufacture,after formation of phosphor 230 and ACA 292. FIG. 25G shows an exampleof an embodiment where contacts 220 are electrically coupled toconductive foil 1910 using ACA 292′. In some embodiments, the conductivefilm may include or consist essentially of aluminum, gold, silver,titanium, copper, or the like. In one embodiment, conductive film 1910includes or consists essentially of aluminum or copper and has athickness in the range of about 1 μm to about 250 μm, or more preferablyin the range of about 5 μm to about 40 μm.

In some embodiments, reflective layer 1910 may be insulating orrelatively insulating. For example, reflective layer 1910 may include adielectric mirror or Bragg reflector, composed of alternating layers ofmaterials with different indices of refraction. Examples of suchmaterials include silicon dioxide, silicon nitride, or mixtures of thesematerials.

In some embodiments, reflective layer 1910 may be a specular reflector,or it may be a diffuse reflector. For example, a reflective layer 1910made from powder may provide a more diffuse reflector while a reflectivelayer 1910 made from a metal foil or film may provide a more specularreflector. Reflective layer 1910 may also include or consist essentiallyof a diffuse reflective film, such as a white film, for example whitePET, other white plastic films, polyster, polypropylene, White97manufactured by WhiteOptics LLC, or MCPET manufactured by Furukawa. Insome embodiments, a white ink or paint may be applied selectively to theback of the white wafer to form reflective layer 1910. In someembodiments, reflective layer 1910 may include or consist essentially ofa polymer or plastic, such as polyethylene, silicone or epoxy or thelike, with a relatively high reflectivity, for example a white diffusereflector such as Dow Corning MS-2002. In some embodiments, the siliconeor epoxy may have a reflectivity greater than about 95% or greater thanabout 95% or greater than about 97%. In some embodiments, reflectivelayer 1910 may include or consist essentially of a white epoxy. In someembodiments, reflective material 1910 may include or consist essentiallyof a thin layer of reflective epoxy or silicone formed over moldsubstrate 410, as shown in FIG. 22A, over which is subsequently formedphosphor 230.

In some embodiments, ACA 292 may be reflective to a wavelength of lightemitted by LEE 210 and/or phosphor 230. In some embodiments, ACA 292 mayhave a reflectivity of greater than 50% or greater than 70% or greaterthan 85% to a wavelength of light emitted by LEE 210 and/or phosphor230.

In another embodiment, the use of materials similar to those describedherein with respect to reflecting materials may be used for otherpurposes, for example to modify other characteristics, for exampleadhesion of cured phosphor 230 to ACA 292. In some embodiments,modification of other properties may be combined with reflectivity;however, this is not a limitation of the present invention, and in otherembodiments it may be a material that is not substantially reflective.For example, a material formed on mold substrate 410 before formation ofuncured phosphor 420 (FIG. 4B) may result in a layer at or near thephosphor/mold substrate interface that reduces the adhesion of curedphosphor 230 to mold substrate 410. In some embodiments, this may be areflective material; however, this is not a limitation of the presentinvention, and in other embodiments it may be a material that is notsubstantially reflective. In some embodiments, this may be a powder, asdiscussed herein, while in other embodiments this may be a film. In someembodiments, this may act like a mold release material or film,discussed herein, except that in some embodiments the material isincorporated into phosphor cured phosphor.

In some embodiments, reflective layer 1910 may include or consistessentially of more than one material or layer, where each layer servesa different purpose. For example, in one embodiment, reflective layer1910 may include or consist essentially of a first reflective layeradjacent to white die 200, and a second adhesion layer, adjacent to thefirst reflective layer, to provide improved adhesion of the reflectivelayer to the underlying substrate or contacts.

As discussed herein, in some embodiments all or a portion of the surfaceof phosphor 230 may be roughened or textured, for example to reduce TIRand increase the light output or to increase adhesion between phosphor230 and an adjacent material, for example to increase adhesion to ACA292. In some embodiments, roughening or texturing may take place duringthe molding process. In some embodiments, all or a portion of the moldsubstrate surface in contact with phosphor 420 may be roughened ortextured to impart such roughened or textured features to cured phosphor230. In some embodiments, such roughening or texturing may beaccomplished after molding, for example by ablation, laser ablation,chemical etching or chemical ablation, plasma exposure, plasma etching,imprinting, indenting or the like. The method of roughening or texturingis not a limitation of the present invention.

In one embodiment, the textured features may have a size in the range ofabout 0.1 μm to about 50 μm and more preferably in the range of about0.5 μm to about 25 μm. In one embodiment, the texture may behemispherical or pyramidal in shape; however, this is not a limitationof the present invention, and in other embodiments the texture may haveany shape. In one embodiment, the texture includes or consistsessentially of a regular or substantially regular pattern, while inother embodiments the texture includes or consists essentially of randomor substantially random features. In some embodiments, the scale of thetexture is advantageously less than about 10% of the height of LEE 210,or less than 5% of the height of LEE 210 or less than 2% of the heightof LEE 210, in order to reduce occlusion or absorption of light emittedby LEE 210.

FIGS. 26A and 26B show two examples of embodiments incorporatingtextured phosphor adjacent to ACA 292. In FIG. 26A a texture 2610 has aregular periodic structure, while the embodiment shown in FIG. 26B hasan irregular or substantially random structure. The structure of FIG.26B also includes reflective layer 1910. While FIG. 26B shows the sideof reflective layer 1910 opposite phosphor 230 as flat, this is not alimitation of the present invention and in other embodiments the side ofreflective layer 1910 opposite phosphor 230 may not be flat, orreflective layer 1910 may be textured by conforming or substantiallyconforming to the textured surface of phosphor 230. For example, FIG.26C shows an embodiment including a reflective layer 1910 with atextured surface adjacent to ACA 292, while FIG. 26D shows an embodimentincluding a reflective layer 1910 with textured surfaces adjacent to ACA292 and phosphor 230. In some embodiments, all of the individualfeatures making up the texture have the same or substantially the sameshape, while in other embodiments the individual features making up thetexture have different shapes. While the structures shown in FIGS. 26Aand 26B show textured phosphor adjacent to substantially all of ACA 292,this is not a limitation of the present invention, and in otherembodiments only a portion of the phosphor adjacent to ACA 292 may betextured.

In the case of the embodiment shown in FIG. 26A, the texture may beformed using a mold having a regular periodic structure formed in themold that is then transferred to the phosphor. In some embodiments, eachindividual feature may have substantially the same shape, but thefeatures do not form a periodic array. In some embodiments, such astructure may be formed by molding using a mold having thosecharacteristics, or by formation of particles or beads on mold substrate410, where each particle or bead has substantially the same shape, butthe position of the beads does not form a regular periodic array, andthen molding over the beads.

In the case of the embodiment shown in FIG. 26B, the texture may beformed using a mold having an irregular or substantially randomstructure of different shapes formed in the mold that is thentransferred to the phosphor. In some embodiments, such a structure maybe formed by formation of particles or beads on mold substrate 410,where each particle or bead does not have the same shape, for example apowder, flake, or fleck and where the position of the particles does notform a regular periodic array.

In some embodiments, a texture may be imparted to cured or partiallycured phosphor by indentation or impression of a textured plate onto thephosphor.

In some embodiments, a material may be formed on mold substrate 410before or as part of the formation of uncured phosphor 420, and aftercuring of the phosphor, all or portions of this material may be removed,leaving voids, pits or indentations in portions of cured phosphor 230.FIGS. 27A-27C show an example of one embodiment of a process to producetexture by removal of material after curing of the phosphor. FIG. 27Ashows mold substrate 410 over which has been formed LEEs 210 andparticles 2710. FIG. 27B shows the structure of FIG. 27A at a laterstage of manufacture. In FIG. 27B uncured phosphor 420 has been formedover mold substrate 410, LEEs 210, and particles 2710 and cured and moldsubstrate 410 has been removed, leaving a structure in which particles2710 are embedded or partially embedded in phosphor 230. FIG. 27C showsthe structure of FIG. 27B at a later stage of manufacture. In FIG. 27Call or a portion of particles 2710 have been removed from cured phosphor230, leaving texture 2610. In some embodiments, particles 2710 may beremoved by etching or dissolving in a solution that does not or thatdoes not substantially affect phosphor 230 and LEEs 210. For example, inone embodiment particles 2710 may include or consist essentially of oneor more water-soluble materials such as polyvinyl alcohol (PVA),ammonium chloride, sodium chloride, flour, corn starch, sucrose, or thelike. In one embodiment, particles 2710 may include or consistessentially of one or more alcohol-soluble materials such as sodiumchloride, ammonium chloride, camphor, castor oil, lithium chloride,lithium iodide, or the like. In one embodiment, particles 2710 mayinclude or consist essentially of a metal and be removed by etching in asuitable wet or dry etchant. For example, in one embodiment particles2710 may include or consist essentially of aluminum and may be removedby etching in hydrochloric acid. The composition of particles 2710 andthe techniques for removing them from phosphor 230 are not a limitationof the present invention.

In some embodiments, phosphor 230 may be textured by etching or removalof portions of the phosphor. In one embodiment, phosphor 230 may be freeetched, that is treated without a mask, while in other embodiments amask may be used as part of the texturing process. Silicone material maybe etched using a variety of techniques, for example usingdimethylacetamide based chemicals or other organic solvents, for exampleDynasolve manufactured by Dynaloy. In some embodiments, the phosphor maybe etched using a dry etch or RIE type etching, for example using anoxygen plasma. In some embodiments, the phosphor may be masked prior toetching, to promote formation of a particular scale of texture. Asdiscussed herein, such texture may be regular or irregular. Formation oftexture may be accomplished, for example by patterning and etching, forexample using lithography combined with a mask. Mask materials mayinclude photoresist, metals or other suitable materials. In someembodiments, formation may be accomplished by etching through a physicalmask or stencil. In some embodiments, a mask may be formed byagglomeration, for example by formation of a relatively thin layer ofmetal on the phosphor, for example gold and then heating to inducecoalescence in the metal to form a relatively random mask which may thenbe used for texture formation.

In some embodiments, all or a portion of the phosphor may be treated toincrease adhesion of phosphor 230 to ACA 292. Such a treatment mayinclude a wet chemical treatment, a plasma treatment, ozone exposure,oxygen plasma treatment or the like. For example, a chemical treatmentmay include a primer such as 1200 OS manufactured by Dow Corning.

As discussed herein, in some embodiments, a white die may include aportion of the phosphor having a texture, or a portion of the phosphorcovered or overlaid with a reflecting layer, or both. In someembodiments, the reflecting layer itself may be textured, while in otherembodiments the texture is separate from the reflecting layer.

While the discussion above has mainly focused on light-emitting devicesthat include a phosphor, this approach may be used as an approach toeconomically make light-emitting devices without the phosphor, where thematerial surrounding the LEE is a transparent material with nolight-conversion material. In some embodiments, examples of suchstructures are similar to the structures shown in FIGS. 11A-11F, butwhere phosphor 230 in these figures is replaced by a transparentmaterial. This may be referred to as a clear die or an ACA clear die. Inthis case, the transparent material may be referred to as a binder or anencapsulant. In this case the structure would appear similar to theexamples discussed above, with the difference being that there is nolight-conversion material present and the color of light emitted by suchdevice is substantially the same as that emitted by the LEE. In someembodiments, other materials may be present in the binder, for examplematerial to scatter the light. Any or all of the variations discussedwith respect to this invention may be used to produce clear dies. Thisapproach permits the low-cost manufacture of clear dies in very largevolumes. In some embodiments, LEE 210 may include or consist essentiallyof an LED. In some embodiments, LEE 210 may emit light in any visiblecolor range, for example, red, orange, yellow, green, amber, blue, etc.,or in wavelengths outside of the visible range, e.g., infrared andultraviolet. In some embodiments, additional elements could be formed aspart of the ACA clear die, for example an optic, similar to thestructures shown in FIGS. 17A-17C, or in some embodiments the clear diecould be co-molded with an optical fiber. The optical fiber may be usedfor example, for out-coupling of light or monitoring of LEE 210 opticalcharacteristics. Such optical fiber coupling may also be used with whitedies or ACA white dies.

While the discussion above has mainly focused on light-emitting devices,embodiments of the present invention may also be used for devices thatabsorb light, for example detectors or photovoltaic devices. Structures,configurations and processes for producing ACA white die describedherein may also be applied for fabrication of embodiments of the presentinvention incorporating one or more light-absorbing elements (LAE). Forexample, in one embodiment a LAE die may have a structure similar tothat shown in FIGS. 2A-2G, 11A-11F, 12A-12C, 13A-13B and 17A-17C. In oneembodiment the LAE may be configured to detect one or more wavelengthsover a wide range of wavelength ranges, both within and outside thevisible light spectrum. In various embodiments the LAE may be configuredto detect UV light, IR light, x-rays, visible light or any portion ofthe electromagnetic spectrum for which a detector is available. In someembodiments, the LAE may include GaAs, InAs, AlAs, GaN, InN, AlN, GaP,InP, AlP, InGaP, InAlP, InGaAlP, ZnO, II-VI materials or the like orvarious combinations of two or more of these materials. The materialfrom which the LAE is composed is not a limitation of the presentinvention.

In some embodiments, the LAE may be a Schottky detector, a p-n junctiondetector, a photoelectric detector, a photocell, a photoresistor, aphotodiode, a phototransistor, a charge-coupled device, a CMOS imager orthe like. The type of LAE and method by which the LAE operates are notlimitations of the present invention.

In one embodiment, the binder is transparent to a wavelength of light tobe detected by the LAE. In one embodiment, the binder surrounding theLAE may be partially absorbing and the absorption band of the binder maybe used to select one or more wavelength ranges to be detected by theLAE from the range of incident wavelength ranges. For example the bindermay effectively act as a low-pass filter, a high-pass filter, a bandpassfilter or various combinations of these.

In some embodiments, the binder may further include other materials toenhance one or more performance aspects. For example, in one embodiment,the binder may include materials to absorb one or more wavelengths oflight, to act as a filter. In one embodiment, the binder includes awavelength-conversion material, similar to that described above. In oneembodiment, this may be used to shift an incident wavelength to adifferent wavelength to be detected by the LAE. For example a phosphormay be added to the binder to shift one or more wavelengths of incidentlight (e.g., blue light) to one or more different wavelengths (e.g.,yellow light) that impinge on the LAE. In this way one or a small numberof the LAEs may be used in combination with a number ofwavelength-conversion materials to produce a family of detectorsspanning a wide wavelength range, without the need to have a relativelylarge number of different LAEs.

As discussed herein with respect to white dies, the binder may beshaped. In some embodiments the binder is shaped to increase thecollection of light by the LAE. In some embodiments the binder iscombined with one or more additives to the binder, for example awavelength-conversion material.

In some embodiments a device may include more than one LAE. In oneembodiment, the different LAEs may detect different wavelengths ordifferent wavelength ranges, for example three different LAEs may detectred, green and blue. In some embodiments the combination may be used asa color sensor by evaluating the relative output signals from the threedifferent LAEs.

In some embodiments the LAE is a photovoltaic device or solar cell, andis designed to produce power from incident radiation (typically, but notnecessarily, in the visible range). Such a photovoltaic device may bemade of a wide variety of materials. In some embodiments, the LAE mayinclude GaAs, InAs, AlAs, GaN, InN, AlN, GaP, InP, AlP, InGaP, InAlP,InGaAlP, ZnO, II-VI materials or the like or various combinations of twoor more of these materials. The material from which the LAE is made isnot a limitation of the present invention. In some embodiments, the LAEis a single-junction solar cell, while in other embodiments the LAE is amulti junction solar cell. As discussed herein with respect tolight-emitting elements and detectors, photovoltaic devices producedusing embodiments of the present invention may include in variousembodiments a transparent binder, additives to the binder,wavelength-conversion materials, shaped binder, optics, multiple LAEs5810 per device, and the like.

In some embodiments, a photovoltaic device made using this invention mayadditionally include one or more optics to increase collection or to actas concentrators. In one embodiment, the optical function for collectionor concentration is carried out using a shaped binder.

In some embodiments, the binder may further include other materials toenhance one or more aspects of the performance of devices. For example,in one embodiment, the binder may include materials to absorb one ormore wavelengths of light, to act as a filter. In one embodiment, thebinder includes a wavelength-conversion material, similar to thatdescribed above with respect to white dies. In one embodiment, this maybe used to shift an incident wavelength to a different wavelength to beabsorbed by a solar cell. For example, a phosphor may be added to thebinder to shift one or more wavelengths of incident light to one or moredifferent wavelengths of light that impinge on the solar cell. In thisway a larger portion of the solar spectrum may be usefully absorbed bythe solar cell. In some embodiments, this may permit the use of a lowercost the solar cell, for example one with fewer junctions. In oneembodiment, more than one different solar cell, each absorbing light ina different wavelength range, may be incorporated into one packageddevice.

Embodiments of the present invention may be applied to devices thatneither emit nor detect light, identified as electronic-only devices,where the purpose of application of this invention is in someembodiments reduction in cost. In various embodiments, a relativelylarge number of electronic devices, specifically chips or discretedevices or integrated circuits may be packaged in a polymer-basedmaterial (like the binder detailed above) using a high-volume, low-cost,base process. In some embodiments of this approach, the binder need notbe transparent but may be translucent or opaque. As discussed hereinwith respect to light-emitting elements, detectors, and photovoltaicdevices, electronic-only devices produced in accordance with embodimentsof the present invention may include additives to the binder, shapedbinder, multiple devices, and the like.

In one embodiment, an electronic-only device of the present invention isa packaged electronic-only device, such as that shown in FIG. 28A, inwhich device 2800 includes electronic-only device 2810 and binder 2820.In some embodiments, electronic-only device 2810 may have a largernumber of contacts than would a light emitter or a detector. For exampleelectronic-only device 2810 may include more than ten contacts or morethan 100 contacts or even larger number of contacts.

FIG. 28B shows another example, device 2801, incorporating a heatspreader 2830. A heat spreader, as utilized herein, is a volume ofmaterial with a relatively high thermal conductivity, in particularhigher than that of binder 2820, which may be used to transfer heat fromelectronic-only device 2810 to ambient or to an additionalthermal-management system. In some embodiments, heat spreader 2830 is ametal, for example Al, Cu, Au, Ag, Cr, or the like. In some embodiments,heat spreader 2830 is a ceramic, for example AlN, SiC, polycrystallineSiC, polycrystalline AlN, or the like. In some embodiments, heatspreader 2830 is a monolithic component, but this is not a limitation ofthe present invention, and in other embodiments heat spreader 2830 maycomprise multiple discrete and separate portions, as shown in FIGS. 28Cand 28D respectively. While heat spreader 2830 is shown as a square orrectangular in FIGS. 28C and 28D, this is not a limitation of thepresent invention, and in other embodiments heat spreader 2830 may haveany shape or size. In one embodiment heat spreader 2830 is a heat pipe.

In another embodiment, a connector may be added to a device, for examplean electronic-only device. In one embodiment, a connector 2840 is addedon top of electronic-only device 2810 and held in place at least in partby the presence of binder 2820, as shown in FIG. 28E.

In another embodiment, one or more devices may be stacked on top of eachother, as shown in FIG. 29. FIG. 29 shows electronic-only device 2810′formed over electronic-only device 2810. FIG. 29 also shows optionalvias through electronic-only device 2810, permitting electrical couplingbetween electronic-only devices 2810′ and 2810. Other methods may beused to electrically couple devices, for example wire bonding, solder,conductive adhesives, etc. While FIG. 29 shows electronic-only device2810 and 2810′ having different sizes, that is not a limitation of thepresent invention, and in other embodiments electronic-only device 2810and electronic-only device 2810′ may have the same or substantially thesame size.

In another embodiment, electronic-only and other (for examplelight-detecting and/or light-emitting) devices may be packaged in thesame binder, as shown in FIG. 30. FIG. 30 shows electronic-only device2810 adjacent to light-detection device 3010. This approach may be usedto provide some additional capability, for example signal conditioning,communications, memory or the like. In one embodiment, electronic-onlydevice 2810 and light-detection device 3010 communicate through each oftheir respective contacts by way of connections on the circuit board towhich they are ultimately mounted. In one embodiment, internalconnection is used, for example similar to the vias shown in FIG. 29 orwire bonds, etc. In some embodiments, all or portions of binder 2820 maybe transparent to a wavelength of light absorbed or emitted by lightdetecting or light-emitting device 3010.

While the discussion herein mainly focuses on down-conversion, that isthe use of a wavelength-conversion material or phosphor to shift a shortwavelength to a longer wavelength, that is not a limitation of thepresent invention, and in other embodiments up-conversion or acombination of up-conversion and down-conversion may be used.

Other embodiments of this invention may have additional or fewer stepsor components or may be modified or carried out in a different order. Ingeneral in the above discussion the arrays of light emitters, wells,optics and the like have been shown as square or rectangular arrays;however, this is not a limitation of the present invention and in otherembodiments these elements are formed in other types of arrays, forexample hexagonal, triangular or any arbitrary array. In someembodiments, these elements are grouped into different types of arrayson a single substrate.

The terms and expressions employed herein are used as terms andexpressions of description and not of limitation, and there is nointention, in the use of such terms and expressions, of excluding anyequivalents of the features shown and described or portions thereof. Inaddition, having described certain embodiments of the invention, it willbe apparent to those of ordinary skill in the art that other embodimentsincorporating the concepts disclosed herein may be used withoutdeparting from the spirit and scope of the invention. Accordingly, thedescribed embodiments are to be considered in all respects as onlyillustrative and not restrictive.

What is claimed is:
 1. An electronic device comprising: a solid shapedvolume of a polymeric binder; suspended within the binder, asemiconductor die having a first face, a second face opposite the firstface, and at least one sidewall spanning the first and second faces, thesemiconductor die being a bare-die light-emitting element comprising aplurality of active semiconductor layers that cooperatively emit light;disposed on the first face of the semiconductor die, at least twospaced-apart contacts each having a terminal end not covered by thepolymeric binder, the contacts each contacting a different activesemiconductor layer of the semiconductor die; and disposed over and inelectrical contact with at least a portion of each of the terminal endsof the contacts, an anisotropic conductive adhesive (ACA), wherein atleast a portion of the polymeric binder is transparent to a wavelengthof light emitted by the light-emitting element.
 2. The electronic deviceof claim 1, wherein the ACA comprises an anisotropic conductive film. 3.The electronic device of claim 1, wherein at least a portion of the ACAopposite the contacts is free and available for electrical connection.4. The electronic device of claim 1, wherein the polymeric binder andsemiconductor die collectively define a rectangular solid havingapproximately 90° corners between adjacent faces thereof.
 5. Theelectronic device of claim 1, wherein at least portions of the contactsprotrude from the polymeric binder.
 6. The electronic device of claim 1,wherein only a portion of each said sidewall protrudes from thepolymeric binder, a portion of each said sidewall being covered with thepolymeric binder.
 7. The electronic device of claim 1, wherein thepolymeric binder comprises at least one of-silicone or epoxy.
 8. Theelectronic device of claim 1, further comprising one or more additionalsemiconductor dies suspended within the polymeric binder.
 9. Theelectronic device of claim 1, wherein the light-emitting elementcomprises a semiconductor material comprising at least one of GaAs,AlAs, InAs, GaP, AlP, InP, ZnO, CdSe, CdTe, ZnTe, GaN, AlN, InN,silicon, or an alloy or mixture thereof.
 10. The electronic device ofclaim 1, wherein the polymeric binder has a thickness between 5 μm and2000 μm.
 11. The electronic device of claim 10, wherein a dimension ofthe polymeric binder perpendicular to the thickness is between 25 μm and50 mm.
 12. The electronic device of claim 1, further comprising anoptical element positioned to receive light from the semiconductor die.13. The electronic device of claim 1, further comprising a reflectinglayer over or within at least a portion of the polymeric binder.
 14. Theelectronic device of claim 13, wherein the reflecting layer is disposedbetween at least a portion of the polymeric binder and at least aportion of the ACA.
 15. The electronic device of claim 13, wherein thereflecting layer comprises at least one of (i) a reflecting film or (ii)a plurality of particles.
 16. The electronic device of claim 13, whereinthe reflecting layer has a reflectivity of at least 40% to a wavelengthof light emitted by the light-emitting element.
 17. The electronicdevice of claim 13, wherein at least a portion of the reflecting layeris electrically conductive and is electrically coupled to at least oneof the contacts.
 18. The electronic device of claim 17, wherein (i) thereflecting layer comprises at least two portions, each portionelectrically coupled to a different one of the contacts and (ii) eachportion of the reflecting layer is electrically isolated from each otherportion.
 19. The electronic device of claim 1, wherein the activesemiconductor layers of the semiconductor die are not disposed on asemiconductor substrate.
 20. The electronic device of claim 1, whereinthe polymeric binder coats the first face of the semiconductor die, theat least one sidewall of the semiconductor die, and at least a portionof the second face of the semiconductor die.
 21. The electronic deviceof claim 1, wherein the terminal ends of the at least two contacts arein physical contact with the ACA.
 22. The electronic device of claim 1,wherein at least a portion of the ACA is not activated to enableelectrical conduction through a thickness thereof to the at least twocontacts.
 23. The electronic device of claim 1, further comprising asubstrate having a plurality of conductive elements disposed thereon,wherein (i) at least two said contacts on the first face of thesemiconductor die are each electrically coupled to a differentconductive element on the substrate via the ACA and (ii) the at leasttwo said contacts are electrically insulated from each other through theACA.
 24. The electronic device of claim 1, wherein the polymeric bindercontains therein a wavelength-conversion material for absorption of atleast a portion of light emitted from the light-emitting element andemission of converted light having a different wavelength, convertedlight and unconverted light emitted by the light-emitting elementcombining to form mixed light.
 25. The electronic device of claim 24,wherein the mixed light is substantially white light.
 26. The electronicdevice of claim 25, wherein the substantially white light has acorrelated color temperature in the range of 2000 K to 10,000 K.
 27. Theelectronic device of claim 24, wherein the polymeric binder comprises aplurality of discrete regions, at least one of which comprises thepolymeric binder without wavelength-conversion material therein.
 28. Theelectronic device of claim 24, further comprising a reflecting layerover or within at least a portion of the polymeric binder, wherein thereflecting layer has a reflectivity of at least 40% to a wavelength oflight emitted by the wavelength-conversion material within the polymericbinder or the light-emitting element.